Component Maintenance Manual With Illustrated Parts List: Part Number 601307-1

DRIESSEN AEROSPACE SYSTEMS, BV DE STEK 1 1771 SP, WIERINGERWERF HOLLAND TEL: +31 227 606 162 FAX: +31
227 606 150 FSCM CODE: VH1D67
COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST
GALLEY G1 PART NUMBER 601307-1
All Rights Reserved Copyright 2008 Driessen. This document is the property of Driessen Aerospace Systems and must not be copied or used, either in whole or part, for any purpose other than that for which it is supplied, without the express written authority of Driessen Aerospace Systems, BV, DE STEK 1, 1771 SP WIERINGERWERF, HOLLAND. TP Page 1 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 RECORD OF REVISIONS INSERTED DATE July 04/08 BY Driessen INSERTED DATE BY
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ISSUE DATE July 04/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 RECORD OF TEMPORARY REVISIONS INSERTED DATE BY REMOVED DATE BY
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 SERVICE BULLETIN LIST
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 LIST OF EFFECTIVE PAGES SUBJECT TITLE PAGE RECORD OF REVISIONS RECORD OF TEMPORARY REVISIONS SERVICE BULLETIN LIST LIST OF EFFECTIVE PAGES TABLE OF CONTENTS PAGE DATE 1 Jul 4/08 Blank Jul 4/08 1 Jul 4/08 Blank Jul 4/08 1 Jul 4/08 Blank Jul 4/08 1 Jul 4/08 Blank Jul 4/08 1 Jul 4/08 2 Jul 4/08 1 2 3 Blank 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1001 1002 1003 1004 1005 1006 1007 1008 2001 2002 2003 2004 2005 2006 2007 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 INSPECTION/CHECK DISASSEMBLY CLEANING SUBJECT PAGE DATE 2008 Jul 4/08 2009 Jul 4/08 Blank Jul 4/08 3001 Jul 4/08 Blank Jul 4/08 4001 4002 4003 Blank 5001 5002 5003 5004 5005 Blank 6001 6002 6003 6004 6005 6006 6007 6008 6009 6010 6011 6012 6013 6014 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08
INTRODUCTION
REPAIR
DESCRIPTION AND OPERATION
ASSEMBLY FITS AND CLEARANCES SPECIAL TOOLS, FIXTURES AND EQUIPMENT SPECIAL PROCEDURES REMOVAL INSTALLATION SERVICING
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TESTING AND FAULT ISOLATION
SCHEMATICS AND WIRING DIAGRAMS
STORAGE
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 SUBJECT REWORK ILLUSTRATED PARTS LIST PAGE DATE 16001 Jul 4/08 Blank Jul 4/08 10001 10002 10003 10004 10005 10006 10007 10008 10009 10010 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TABLE OF CONTENTS INTRODUCTION 1. 2. Introduction Abbreviations 1 2
DESCRIPTION AND OPERATION 1. 2. 3. Description Operation Galley Specications 2 18 19
TESTING AND FAULT ISOLATION 1. Test and Fault Isolation A. B. C. D. 2. Electrical Tests Electrical System Functional Tests Plumbing System Function Test Compartment Functional Test 1001 1002 1003 1004 1005 1007 1007
Galley System Fault Isolation A. Fault Isolation
SCHEMATICS AND WIRING DIAGRAMS 1. Schematics and Wiring Diagram A. Electrical Continuity 2001 2001
DISASSEMBLY 1. Disassembly 3001
CLEANING 1. Cleaning A. B. C. D. Door Assembly Plumbing Installation Electrical Installation Structure Assembly 4001 4002 4003 4003 4003
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 INSPECTION/CHECK 1. Inspection/Check A. B. C. D. E. F. G. H. I. J. K. REPAIR 1. Repair No. 1 - Rivet Parts Repair A. 2. Rivet Repair 6001 6001 6002 6002 6003 6003 6004 6005 6006 6006 6006 6006 6007 6008 6008 6009 6009 6010 6011 6013 6013 6013 6014 6014 Structure Joints Upper and Lower Attachments Rubstrips, Slide Extractors and T-dividers Workdecks and Workcounters Air Filters and Vents Mechanical Electrical Plumbing Placards Refrigeration 5001 5002 5003 5003 5003 5003 5003 5004 5004 5005 5005 5005
Repair No. 2 - Weld Parts Repair A. Weld Repair
3.
Repair No. 3 - Panel Repairs A. B. C. Damaged Honeycomb Panel Repair Damaged Honeycomb Panel Repair Procedure Inserts Replacement Repair
4.
Repair No. 4 - Decorative Area Repairs A. B. C. D. Metal Decor Panels Repair Stainless Steel Surfaces Repair Satin-Brushed Stainless Steel Surfaces Repair Painted Surfaces Repair
5.
Repair No. 5 - Decorative Materials Replacement A. B. C. D. E. Damaged Decorative Laminates Removal Wall Cleaning Filler Material Application Adhesive Decorative Covering Material Application
6.
Repair No. 6 - Corrosion Removal A. B. Door Assemblies and Panels Corrosion Removal Non-appearance Surfaces Corrosion Removal
7.
Repair No. 7 - Placard Replacement A. Placard Replacement
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 ASSEMBLY 1. Galley System Assembly 7001
FITS AND CLEARANCES 1. Torque Values 8001
SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1. Special Tools, Fixtures and Equipment 9001
SPECIAL PROCEDURES 1. Special Procedures 11001
REMOVAL 1. Removal 12001
INSTALLATION 1. Installation 13001
SERVICING 1. Servicing A. B. C. STORAGE 1. Storage after Assembly A. REWORK 1. Rework 16001 Packing and Storage Procedures 15001 15001 In-service Cleaning Field Maintenance Periodic Maintenance 14001 14001 14001 14002
ILLUSTRATED PARTS LIST 1. 2. Introduction Numerical Index 10001 10004
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 INTRODUCTION TASK 25-36-03-871-801-A01 1. Introduction A. General (1) (2) (3) (4) This Component Maintenance Manual (CMM) is written with reference to the requirements of the ATA specication iSpec2200 and in AECMA Simplied Technical English (ASD STE). The manual gives maintenance on the component in a workshop. It does not give maintenance on the component when it is installed in the aircraft. Only approved persons with the necessary skills must be used for the maintenance procedures given in this manual. Maintenance Task Oriented Support System (MTOSS) task and subtask identication is used in this manual. The maintenance tasks and other data have special MTOSS numbers for the use of Electronic Data Processing (EDP). The MTOSS numbers can be ignored by the user of the manual. This manual contains: Technical data for the component This CMM contains, as applicable, fully descriptive and operating notes, complete with procedures for testing and fault isolation, disassembly, check, removal and repair of parts and assembly of the unit given when used on the applicable type or series of aircraft. An Illustrated Parts List (IPL) with data for the component parts. Parts are identied in all sections of the manual by the IPL gure and item number.
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(6) B.
We veried the disassembly, testing and assembly procedures by actual performance.
How to Use the Manual (1) This Component Maintenance Manual gives instructions for maintenance of Galley G1 part number 601307-1. Instructions are given for maintenance duties ranging from on-board cleaning through simple checks and small repairs to full disassembly of the unit for comprehensive shop overhaul. Repairs beyond the scope of this manual must be referred to the manufacturer. Make sure the manual contains the information applicable to your component. Look on the title page for the part number. If you need to identify a part or nd a part number, refer to the IPL, which has an introduction to show the procedure. The instructions in this manual must be used for all the component maintenance. Read all the applicable warnings and cautions before you do the work on the component. Make sure that this copy of the CMM is at correct revision status.
(2) (3) (4) (5)
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-871-802-A01 2. Abbreviations A. List of Abbreviations Table 1 - List of Abbreviations A A/C AC AECMA AR ASSY ATA BF BFE C CCW CFM CG CL CMM COMPT CW DC EDP ESDS EQUIP ETC F FAA FIG. FPM Ampere Aircraft Alternating Current Aircraft European Contractors Manufacturers Association As Required Assembly Air Transportation Association of America Buyer furnished Buyer furnished equipment Celsius Counter-clockwise Cubic feet per minute Center of gravity Centerline Component Maintenance Manual Compartment Clockwise Direct Current Electronic Data Processing Electro Static Discharge Sensitive Equipment Et cetera (and so on) Fahrenheit Federal Aviation Administration Figure Feet per minute INTRODUCTION Page 2 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 FPS FWD GND GPM Hg Hz ID IN INSTL IPL kVA LBL LBS LEP LH MAX M/F MIN MISC MM MS MTOSS NA NAS NHA No. NS/FSB OCM OUTBD PN Feet per second Forward Ground Gallons per minute Inches of mercury Hertz (cycles per second) Identication Inch Installation Illustrated Part List Kilovolt amperes Left butt line Pounds List of Effective Pages Left-hand Maximum Manufactured Form Minimum Miscellaneous Millimeter Military specication Maintenance Task Oriented Support System Not Applicable National Aerospace Standard Next Higher Assembly Number No Smoking/Fasten Seat Belt Oven Control Module Outboard Part Number INTRODUCTION Page 3 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 psia psid psig PWR RBL Ref. Req. RF RH rms ROR RTR SB SBL SF SFE SPS STA STD STOW TR TOC TYP V W WL WT Pounds per square inch absolute Pounds per square differential pressure Pounds per square inch gauge Power Right butt line Reference Required For Reference only Right Hand root mean square Record Of Revisions Record of Temporary Revisions Service Bulletin Service Bulletin List Supplier furnished Supplier furnished equipment Standard Production Specication Station Standard Stowage Temporary Revision Table Of Contents Typical Volts Watts Waterline Weight
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 DESCRIPTION AND OPERATION TASK 25-36-03-870-801-A01 1. Description A. General (1) (2) The Galley G1 assembly, part number 601307-1 is a major component installed in the aircraft. The galley is an integrally-bonded structure fabricated from berglass-sandwich panels and aluminum extrusions. The panel joints are accomplished by "mortise and tenon joints" and the berglass phenolic/Nomex honeycomb panels are fabricated in the accordance with Driessen Standard Process Specication.The Galley design is modular in nature with functional components. The galley helps for storing and preparing food and beverages served during ight. The galley also gives miscellaneous storage space for passenger control items, and waste container used for storage and disposal of foodstuff and unwanted material collected during ight. Removable serving carts lets rapid replenishment of food, beverages and dry stores during pre and post-ight operations. For more information refer to the Driessen drawing number 601307 and (Ref. TABLE-2). Table 2 - Associated Documents GALLEY G1 AIRBUS ASSOCIATED DOCUMENTS GALLEY AND GALLEY INST. FRAME SPECIFICATION GALLEY STANDARD SPECIFICATION ELECTRICAL INSTALLATION REQUIREMENTS CUSTOMER INTERFACE SPECIFICATION GALLEY COOLING FRAME SPECIFICATION INTERIOR COLOR SPECIFICATION DRIESSEN ASSOCIATED DOCUMENTS GENERAL ARRANGEMENT FINAL ASSEMBLY BONDED STRUCTURE ELECTRICAL DIAGRAM ELECTRICAL INSTALLATION ELECTRICAL ASSEMBLY PLUMBING DIAGRAM PLUMBING INSTALLATION PN 601307-1 DOCUMENT NO. 2530 M1F 0003 00 SEE DDP NA 9200 M1F 0200 00 ISSUE 2 2530 M1I 0713 00 SEE DDP 2534 M1F 0001 00 SEE DDP ICS 07/59 DRAWING NO. / PART NO. 600307-3 601307-1 604307-1 606307-3 607307-11 608307-11 609307-11/-21 610307-11
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 GALLEY G1 REFRIGERATION DIAGRAM REFRIGERATION INSTALLATION PLACARD INSTALLATION TRIM AND FINISH INSTALLATION VENTILATION INSTALLATION B. Electrical Power (1) Electrical power, furnished as 3-phase, 115/200 VAC, 400 Hz, from the main power of aircraft system, is received in the galley control panel and distributed to the various galley components with circuit breakers and switches. One or two electrical control panel is/are installed in the galley and be pulled out for access to components by removing fasteners. All galley electrical components are controlled from the control panel. For electrical bonding interface, miscellaneous connection and power connection attachment points (Ref. Fig. 2001). PN 601307-1 612307-3 613307-11 618307-11 619307-3 621307-11 628307-11/ 632307-11
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(3) C.
Plumbing (1) The galley receives potable water through a quick-disconnect tting and a shut-off valve. Waste water and liquids from coffee makers, water boilers, water lters and countertops are drained through galley mounted drainage lines into the aircraft drain system. For water supply and drain line connection attachment points (Ref. Fig. 2).
D.
Refrigeration (1) Refrigeration equipment provides chilled air from air chiller to refrigerator carts through chilled airducting. It provides the necessary cooling for preservation of foods and beverages stored withinthe carts (Ref. Fig. 3).
E.
Lighting (1) General illumination for galley area is done with light xtures in the aircraft ceiling. A light xture, located above the counter, directly illuminates the workdeck.
F.
Galley Insert Equipment and Provision (1) For the galley insert equipment, provision and compartment locations in the galley (Ref. Fig. 1) and (Ref. TABLE-3).
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Table 3 - Required Inserts TYPE DESCRIPTION CODE VENDOR/PN DIMENSIONS WIDTH HEIGHT DEPTH mm mm (in.) mm (in.) (in.) Carts Full size meal cart (Atlas) Half size meal cart (Atlas) Full size waste cart (Atlas) Half size waste cart (Atlas) Containers Standard container (Atlas) FS1 (Primary) HS1 (Alternate) FW1 (Alternate) HW1 (Primary) STD1 (Primary) Driessen TK500041 Driessen TL500037 Driessen TG500014 Driessen TH500018 Driessen BB001265 Driessen DA001210 Driessen BE001090 Driessen DD001050 Driessen L13471-40 NA 300.80 (11.84) 300.80 (11.84) 300.80 (11.84) 300.80 (11.84) 293.00 (11.54) 274.00 (10.79) 293.00 (11.54) 231.00 (9.09) 163.50 (6.44) NA 1030.00 (40.55) 1030.00 (40.55) 1030.00 (40.55) 1030.00 (40.55) 278.00 (10.94) 105.00 (4.13) 278.00 (10.94) 99.00 (3.90) 331.00 (13.03) NA 561.00 (22.09) 271.5 (10.69) NA 810.00 (31.89) 404.00 (15.91) 810.00 (31.89) 404.00 (15.91) 396.00 (15.59) 379.00 (14.12) 399.00 (15.71) 316.00 (12.44) 293.50 (11.56) NA 550.00 (21.45) 663.4 (26.12) NA 5 QTY
Standard drawer Part of std container (Atlas) Ice container (Atlas) Ice drawer (Atlas) Beverage maker Water boiler Rail assembly Ovens NA Convection oven (LH hinged) Air chiler (4500 BTU/h) Part of galley ICE1 (Alternate) Part of ice container BEV1 (Primary) R1 OV1 (Primary) Part of aircraft WL1
(10) 0 (0) 2 NA 2
B/E Aerospace 285.00 4310000-00(11.22) 55 B/E Aerospace 430.80 236-508 (16.96) AES LD0500-120 NA
Chillers Work lights
1 1
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 G. Galley Upper and Lower Attachments (1) H. The galley uses six hard points ttings and two utter point ttings for attachment to the aircraft (A/ C) oor. Upper attachment is done by pip-pins to an upper support bracket (Ref. Fig. 1).
Safety Considerations (1) The galley assembly includes safety design features, such as rounded external corners, ush ttings, minimum projections and component kept devices to prevent objects from ying when ultimate loads are applied. All movable components of the galley, such as hinged doors, include a positive latching provision capable to keep the component in the closed or stowed position during acceleration. All doors that are in access when installed include secondary latches. General warning placards, emergency placards, crew instructions placards, and weight placards are put in conspicuous places and are readable from correct working positions. Material used in assembly of the galley is to be re retardant. Additionally, areas subject to re danger such as waste container stowage compartments, waste receptacles, etc., are designed and manufactured to contain and prevent the apply of re.
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(3) (4)
I.
Maintainability (1) The galley is designed so that no special tools are necessary for inspection, adjustment, servicing, removal and replacement of parts. Convenient access is given to the attached ttings and various servicing connections at the airplane interface.
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General Arrangement (Sheet 1 of 9) Figure 1/GRAPHIC 25-36-03-991-001-A01
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General Arrangement (Sheet 2 of 9) Figure 1/GRAPHIC 25-36-03-991-001-A01 DESCRIPTION AND OPERATION Page 6 Jul 4/08
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Plumbing Diagram (Sheet 1 of 2) Figure 2/GRAPHIC 25-36-03-991-002-A01
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Plumbing Diagram (Sheet 2 of 2) Figure 2/GRAPHIC 25-36-03-991-002-A01
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Refrigiration Diagram Figure 3/GRAPHIC 25-36-03-991-003-A01
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-870-802-A01 2. Operation
WARNING: DO NOT USE SIDE-HINGED DOORS AS A BRACE OR HANDHOLD. DO NOT USE DOORS AS A STEP LADDER. CLOSET DOORS ARE DESIGNED TO BE USED IN SUCH A MANNER AND SUCH USE CAN RESULT IN INJURY TO PERSONNEL, AS WELL AS DAMAGE TO THE UNIT. CAUTION: IF ITEMS DEPOSITED WITHIN A STORAGE COMPARTMENT ARE TOO NUMEROUS OR BULK TO LET THE DOOR TO CLOSE. DO NOT TRY TO FORCE THE DOOR CLOSED. FORCED CLOSURE OF DOORS CAN RESULT IN TOO MUCH WEAR AND/OR DAMAGE TO THE GALLEY. REMOVE AS MANY ITEMS AS NECESSARY TO LET SUFFICIENT CLEARANCE FOR THE DOOR TO CLOSE. A. Doors (1) B. Turn the retainer turn clockwise to unlock the doors with retainers. When unlocked, operate the slide latches to open the doors. Turn the retainers only to open the doors without latches.
Electrical Circuits (1) (2) (3) The control panel contains switches, circuit breakers and indicator lights that control applications of AC and DC power to various electrical components. Three-phase 115/200 VAC, 400 Hz power and sometimes 28 VDC or 6 VDC power from the aircraft electrical power system is applied for operation of the electrical inserts and worklights. The control panel manages the application of electrical power to the applicable component by switches.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-870-803-A01 3. Galley Specications A. Leading Particulars For the list of leading particulars of the galley (Ref. TABLE-4). Table 4 - Leading Particulars Unit Part Number Height Width Depth Estimated Gross Weight 880.90 kg (1938.00 lbs)
Galley G1
601307-1
2125.90 mm (83.69 in.)
2253.40 mm (88.72 in.)
990.60 mm (39.00 in.)
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TESTING AND FAULT ISOLATION TASK 25-36-03-810-801-A01 1. Test and Fault Isolation A. Reason for the Job These procedures are done to test the galley before installation in the aircraft. If all necessary test procedures cannot be completed successfully, the galley component is defective. For possible fault causes and corrections (Ref. TASK-25-36-03-810-802-A01). B. Job Set-up Information (1) Tools, Fixtures and Equipment NOTE: Equivalent alternatives can be used. Table 1001 - Test Equipment Equipment MANUFACTURER ( Part Number ) RANGE / RATING Not Applicable 0 kV 4.0 kV 20 milliOhms 2000 milliohms
Fixture (mounting or holding) for Locally Fabricated each structure, subassembly Dielectric Test Device Digital Ohmmeter Digital Multimeter Insulation & Continuity Tester Ammeter 3-Phase Rotation Indicator Converter Vacuum Pump Anemometer Water pump, incl. pressure gauge and water tank Stop Watch Thermometer/Hybrid Recorder Compressed Air Megger (model: Flash tester FT 4) Megger BT 51 Fluke 25 Megger BM 200 Commercially Available Siemens A 1504 Merlin Gerin SFC400 Ghibli AS59 Testo 435 URACA EP601 Commercially Available Omega Technologies RD3752
0 1000 megaOhms
115/200 V, 400 Hz, 3-phase 2000 W
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (2) Consumables (a) (3) None
References (a) None
C.
Job Set-up None
D.
Procedure Subtask 25-36-03-750-001-A01 (1) Electrical Tests (a) Electrical continuity test: NOTE: This is to be done after re-installation of the electrical panel. 1 (b) Use the multimeter to examine each lead, system input and output for electrical continuity (Ref. Fig. 2001).
Electrical bonding test: NOTE: This is to be done after installation of the galley. 1 2 Measure the resistance value between the galley main static ground stud and a point on the aircraft static ground. This value must not be more than 2.5 milliohms. Measure the bonding from relevant conductive point on the insert to the galley main static ground stud. This value must be 15 milliohm or less (ve milliohm internal to the insert. 10 milliohm from insert to galley main static ground stud). Measure the electrical bonding from relevant galley structure to the galley main static ground stud. This value must be 10 milliohm or less. Measure the bonding from water supply line to the galley main static ground stud. This value must be 15 milliohm or less. Reject the ground resistance if the maximum given value is exceeded. a b Take applicable corrective action to rework or replace. Upon completion of rework or replacement, do the test again.
3 4 5
(c)
Dielectric Strength Test: NOTE: This is to be done, after installation of the galley. WARNING: DISCONNECT ALL SENSITIVE COMPONENTS NOT ABLE TO WITHSTAND 1500 VAC/50 Hz OR 60 Hz, SUCH AS INSERTS, BALLAST AND INDICATOR LIGHTS FROM THE GALLEY ELECTRICAL SYSTEM. 1 2 Set the circuit breakers and the switches to ON position. Attach the terminals of the dielectric strength tester on: a b Mutually insulated parts. Each power wire and a ground stud or connection pin.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 3 4 Keep 1500 VAC/50 Hz or 60 Hz at a uniform rate of 250 500 volts per second. Keep at 1500 VAC for a period of one minute.
CAUTION: REPEATING DIELECTRIC STRENGTH TESTS MUST BE CONDUCTED AT 80% OF THE SPECIFIED VOLTAGE. 5 Any evidence of arcing, sparking or breakdown, current leakage is more than 2.0 milliamperes, or other evidence of insulation damage must constitute a failure as given below: a b 6 (d) Take applicable corrective action. Test must be performed again, after corrective action or work is done again.
Wire harness which passes this test, is immediately tested for insulation resistance, before the test equipment is disconnected.
Insulation resistance test: NOTE: This is to be done after the dielectric test. Test the wire harness, which passed the dielectric strength. 1 2 3 4 Make sure all inserts, including the ballast and indicator light which are disconnected from the galley electrical system. Disconnect if needed. Make sure that the circuit breakers and switches, that are set to OFF position, as needed. Test the harness of wire-to-wire, and wire-to-ground, use 500 VDC. Insulation between mutually insulated parts must be a minimum of 200 megaohms. Connect all the inserts again, when all wiring harnesses have been successfully tested. Set the circuit breakers and switches to ON position.
Subtask 25-36-03-750-002-A01 (2) Electrical System Functional Tests (a) Starting the test: 1 2 Open all galley circuit breakers. Keep 115/200 VAC, 400 Hz, or 28 VDC power to the galley-to-aircraft interface connector. Close the galley circuit breaker located in the cockpit to give power to the galley. Put off FEEDER ENERGIZED circuit breaker. FEEDER ENERGIZED indicator will illuminate. Switch-off main power RELAY and LIGHT circuit breaker. Turn on main power switch, the indicator will illuminate. Put off DC POWER circuit breaker. NOTE: The electrical control panel must show correct function of all indicator lights, switches and circuit breakers. (b) Installed inserts operation: 1 Oven a Shut-off the oven circuit breaker. If applicable, set the outlet oven switch to oven position. TESTING AND FAULT ISOLATION Page 1003 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 b c d e 2 Place the oven power switch in ON position. The power switch will light up when the power is on. Set the heat selection button high. The heat selection switch will light up and the oven will begin to heat. Return the oven power switch to OFF position. The light is switched off and the oven will cool. Open the oven circuit breaker.
Beverage Maker Functional Test a b Close the coffee maker circuit breaker. Place the coffee maker power switch in the ON position. The white POWER and amber HEATING indicator lights will come on and the water in the unit will begin to heat. Return the coffee maker power switch to the OFF position. The white POWER and amber HEATING indicator lights will go off and the water in the unit will cool. Open the coffee maker circuit breaker.
c d 3
Work Light Functional Test a b c d e f g Close the circuit breaker for the area light. Set the area light switch rst OFF position. Set the switch to the DIM position. Set the switch to the BRT position. Return the switch to OFF position. Make sure the level of lighting increase or decrease in brightness accordingly. Open the circuit breaker work light.
Air Chiller Functional Test a b c d Close the air chiller circuit breaker found at the electrical panel. Turn the chiller to ON position found at the electrical panel a indicator light must be on. Cold air must be blowing to the ducts and through the refrigerated components within 30 seconds. Check the temperature inside the compartment using a thermometer, the reading should be atleast 40 degrees Fahrenheit.
Subtask 25-36-03-750-003-A01 (3) Plumbing System Function Test (a) Test the water supply system (Ref. Fig. 2) as follows: 1 2 3 Supply catch basins and an external water tank to collect water drainage from the system. Remove all inserts. Turn water shut-off valve to OFF position. TESTING AND FAULT ISOLATION Page 1004 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 4 5 6 7 8 9 10 11 12 Connect the water source to the galley inlet compressor. Set water pressure to 125 psi (8.6 bar). Turn the water shut-off valve to ON position for ve minutes and examine all connections for leaks. Turn the water shut-off valve to OFF position. Install the insert equipment (coffee makers, water boilers etc.). Set water pressure to 25 psi (1.7 bar). Turn the water shut-off valve to ON position. Make sure free ow of water from the insert equipment and the spigot. Examine all connection for leaks. Remove the insert equipment. The design of the water source interface between the galley plumbing system and the insert equipment is such that removal of the inserts automatically shuts off the water supply at the interface. Open the drain valve to drain the water in the system.
13 (b)
Drain system test (Ref. Fig. 2) 1 2 3 4 5 6 7 8 9 10 Supply catch basins and an external water tank to collect water drainage from the system. Plug the drainage system at the end of the outlet tting. Connect the water source to the galley water inlet connector. Fill the sump and drain lines with water and examine all connections for leaks. Put water into the drain system through the water boiler or coffee maker drain line. Make sure overow only occurs throughout the workcounter sump. Plug all drain lines with applicable plug and apply 5 psig (0.345 bar) to the drainage system for one minute. Examine the drain system for ruptures, kinks or distortion. Disconnect the water supply. Remove all plugs from the drain lines to drain the system.
Subtask 25-36-03-750-004-A01 (4) Compartment Functional Test (a) (b) (c) Rotate each retainer and make sure that it remains in both the open and closed positions. Tap the center of the door lightly. There should be no excessive rattling. Unlatch and open each door fully one-at-a-time. 1 2 3 The latch should release smoothly. The door should close completely without any binding or misalignment. Each primary and secondary latch must smoothly and fully engage without marring the face trim.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 4 (d) Doors must not strike any adjacent surface when open; unless, a bumper is provided to act as a door stop.
Check any drawers in the unit. 1 2 3 4 The low-friction slides on the drawers should operate smoothly. The positive locking mechanism should engage when in the closed position. The open position shop should assure the drawer remains in the unit even when open. There must be no excessive transverse or vertical movement.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-810-802-A01 2. Galley System Fault Isolation A. Reason for the Job The testing lets to nd failures or defective operation of the galley system. After the test is completed, do the fault isolation procedure to nd which components or parts are the cause for the defects. B. Job Set-up Information (1) Tools, Equipment and Consumables (a) (2) No special tools, equipments or consumables are necessary for fault isolation of galley system.
References (a) None
C.
Procedure Subtask 25-36-03-810-001-A01 (1) Fault Isolation NOTE: After partial or full dis-assembly, test the unit. Table 1002 - Fault Isolation Chart FAULT Oven fails to heat. CAUSE Power switch is not ON. Circuit breaker is OPEN. Switch or circuit breaker is defective. Module is damaged or defective. Power switch is not ON. Circuit breaker is OPEN. Switch or circuit breaker is defective. Module is damaged or defective. Compartment too full to close the door. Attaching screws are loose. Hinged pin is damaged. Lighting element is burnt out. Circuit breaker is OPEN. Switch or circuit breaker is damaged or defective. RECTIFICATION Turn ON. CLOSE the circuit breaker. Replace the damaged or defective component. Refer to combo unit manufacturer's product data. Turn ON. CLOSE the circuit breaker. Replace the damaged or defective component. Refer to hot cup manufacturer's product data. Remove items until space is sufcient. Tighten screws on both the door and, galley structure. Replace the hinge pin. Replace the ballast and/or bulb. CLOSE the circuit breaker. Replace the damaged or defective component.
Chiller fails to operate.
Galley doors does not close correctly.
Galley lights does not illuminate.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 FAULT Water Boiler CAUSE POWER switch is not ON. Circuit breaker is OPEN. Switch or circuit breaker is damaged or defective. Module is damaged or defective. RECTIFICATION Turn ON. CLOSE the circuit breaker. Replace the damaged or defective component. Refer to coffee maker manufacturer's product data.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 SCHEMATICS AND WIRING DIAGRAMS TASK 25-36-03-800-801-A01 1. Schematics and Wiring Diagram A. Reason for the Job Examine each lead, system input and output for electrical continuity. This section gives details of electrical connections, equipments, wire, ground, splice and terminal (Ref. Fig. 2001). If all necessary test procedures cannot be completed successfully, the galley of component is defective. For possible fault causes and corrections (Ref. SUBTASK-25-36-03-810-001-A01). B. Job Set-up Information (1) Tools Equipment and consumables (a) (2) No special tools, equipments or consumables are necessary for schematics and wiring diagram.
References (a) None
C.
Job Set-up None
D.
Procedure Subtask 25-36-03-750-005-A01 (1) Electrical Continuity (a) Examine each lead, system input and output for electrical continuity (Ref. Fig. 2001).
SCHEMATICS AND WIRING DIAGRAMS Page 2001 Jul 4/08
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Schematics and Wiring Diagram (Sheet 1 of 8) Figure 2001/GRAPHIC 25-36-03-991-004-A01
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 DISASSEMBLY TASK 25-36-03-000-801-A01 1. Disassembly A. General TBD
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DISASSEMBLY Page 3001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 CLEANING TASK 25-36-03-100-801-A01 1. Cleaning A. Reason for the Job The galley must be cleaned before it is checked or repaired. Cleaning will get defects and/or damage as well as the size and location of necessary repairs. Cleaning removes unwanted material which can damage the performance and appearance of the galley. B. Job Set-up Information NOTE: Only use recommended cleaning agents and materials (or applicable equivalents). You must obey with all cautions and warnings. NOTE: Equivalent alternatives can be used for listed items. (1) Tools, Fixtures and Equipment (a) (2) No special tools or equipments are necessary for cleaning.
Consumables
WARNING: SOME AGENTS AND MATERIALS CAN BE DANGEROUS TO DECORATIVE TRIMS AND/OR FINISHES, AS WELL AS DANGEROUS TO PERSONNEL, IF HANDLED INCORRECTLY. Table 4001 - Recommended Cleaning Agents and Materials MATERIAL Air, compressed Aliphatic Naphtha Benzene Brushes, small softbristled non-metallic Cleaner, degreaser Kleenol-30 Federal Specication TT-N-95 Federal Specication VV-B-230 IDENTIFICATION SOURCE Any approved source Commercially available Commercially available Commercially available Mission Kleensweep Prod. 2434 Birk Dale, Los Angeles, CA. Commercially available Commercially available MIL-C-38334 Super soilax or Electrol-Sol Lysol Federal Specication O-E-760 Federal Specication TT-B-846 Commercially available Commercially available Commercially available Commercially available Commercially available CLEANING Page 4001 Jul 4/08
Chlorine compound Cloth, lint-free Compound, corrosion removing Detergent, commercial Disinfectant Ethanol Alcohol Isobutyl Alcohol
Clorox or HTH
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 MATERIAL Isopropyl Alcohol Solvent IDENTIFICATION Federal Specication TT-I-735 Rho-clene 7688 SOURCE Commercially available Rho-Chem Corp. 425 Isis Avenue Inglewood, CA Commercially available Commercially available
Toluene Xylene (3) References (a) C. None
Federal Specication TT-T-584 Federal Specication TT-X-916
Job Set-up Do these steps at all time the galley is disassembled, partial or full overhaul of the galley is done. Thoroughly clean and sanitize the areas.
D.
Procedure
WARNING: PREVENT BREATHING THE VAPORS OR FUMES FROM CLEANING SOLVENT. GOGGLES, GLOVES, MASK AND PROTECTIVE CLOTHING ARE TO BE WORN TO PREVENT IRRITATION FROM LONG TOUCH WITH CLEANING AGENTS. CLOTHES MUST BE CHANGED IF SOLVENTS ARE SPILLED ON THEM. PROTECTIVE EYE SHIELDS OR GOGGLES MUST BE WORN WHEN CLEANING WITH COMPRESSED AIR. CONTAMINATION AND/OR HIGH PRESSURE AIR CAN CAUSE DANGEROUS EYE INJURY. PERSONNEL MUST BE WARNED OF AREAS WHERE DANGEROUS MATERIALS OR PROCEDURES ARE IN USE. CAUTION: DO NOT LET CLEANING FLUIDS TO FLOW INTO CONNECTORS, SWITCHES, TUBING COVERING WIRES OR ELECTRICAL PANELS. USE ONLY RECOMMENDED CLEANING AGENTS OR EQUIVALENTS WITH SPECIFIED INSTRUCTIONS TO PREVENT DAMAGE TO THE DECORATIVE FINISHES AND TRIM. SMALL PARTS CAN EASILY BE DAMAGED BY HOLDING THE COMPRESSED AIR JET NOZZLE TOO CLOSE. USE BRUSHES CAREFULLY ON EASILY DAMAGEABLE PARTS. Subtask 25-36-03-110-001-A01 (1) Door Assembly (a) (b) (c) (d) Remove stubborn dirt with a solution of detergent in hot water. Use instructions of manufacturer on container for correct proportions. After cleaning fully, use hot water and a clean-soft cloth to clean all surfaces. Dry the door assembly unit with a clean, lint-free cloth. Use liquid disinfectant to clean the door assembly as follows: 1 Wash in a solution of: Five tablespoons of liquid disinfectant (lysol or equivalent) to each gallon of distilled water or Seven tablespoons for each ve liter of distilled water.
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CLEANING Page 4002 Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 2 3 Rinse the door assembly for ve minutes in running water. Dry the door assembly unit with compressed air and/or clean with a clean lint-free cloth.
Subtask 25-36-03-110-002-A01 (2) Plumbing Installation (a) (b) (c) Remove sump screens and contamination from the plumbing installation. Do a periodic check, and clean drain strainers for collected waste. Use liquid disinfectant solution to ush the plumbing assemblies fully, for procedure (Ref. SUBTASK-25-36-03-110-001-A01).
Subtask 25-36-03-140-001-A01 (3) Electrical Installation
CAUTION: DO NOT USE METAL TOOLS TO REMOVE UNWANTED SUBSTANCES FROM ELECTRICAL SOCKETS OR ELECTRICAL CONTACTS. DAMAGE TO CONTACT PLATING WILL CAUSE CORROSION. SOCKET WITH INDICATION OR CORRODED CONTACT MUST BE REPLACED. (a) Use a soft brush and vacuum cleaner to remove the dust and grit from electrical parts.
CAUTION: ELECTRICAL PARTS WHICH DO NOT BECOME CLEAN BY USING A CLOTH, MUST BE REPLACED. DO NOT USE CLEANING AGENTS. (b) Clean all accessible areas with a clean, lint-free cloth.
Subtask 25-36-03-140-001-A01 (4) Structure Assembly
CAUTION: STRUCTURE ASSEMBLIES ARE FABRICATED FROM A MULTI-PLY HONEYCOMB PANEL. DO NOT USE CLEANING PROCEDURES GIVEN FOR METAL PARTS (SUCH AS FITTINGS, ANGLES, ETC.) FOR DAMAGE TO THE DECORATIVE FINISH OF THE HONEYCOMB PANELLING MAY RESULT. (a) Clean panels 1 2 3 4 5 (b) Remove dirt, grease and oil deposits from panelling with a clean cloth moist with foam cleaner or a detergent. Stubborn stains must be cleaned with abrasive cleaning agents, such as household scouring powder (ammoniated or chlorinated) in combination with a moist cloth. Use carefully to prevent damage to decorative surfaces. Do not use other type of abrasive souring pad. Use an applicable cleaning solvent to remove difcult scuffs and/or stains from surfaces which appear metallic. Use a soft, lint-free cloth soaked in ethyl alcohol to remove solvent. Stubborn residue must be removed with foam cleaner or a detergent.
Clean metal parts 1 2 Remove dirt, grease and oil from metal structural parts with a clean cloth saturated with ethyl alcohol. Clean with a lint-free cloth to remove solvent lm or residue.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 INSPECTION/CHECK TASK 25-36-03-210-801-A01 1. Inspection/Check A. Reason for the Job The inspection/check lets the user to nd a defect which cause incorrect operation of the unit. The user thus makes sure that the removed parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and consumables (a) (2) No special tools, equipments or consumables are necessary for the inspection/check.
References NAME Fits and Clearances
REFERENCE Page block 8001 C. Job Set-up
Do a visual inspection of all parts for physical damage, such as nicks, dents, delamination, cuts, cracks, burns, scoring, corrosion, stripped or crossed threads, and other defects. Use a strong light source. If it is not serviceable replace the part. For inspection and maintenance (Ref. TABLE-5001).
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INSPECTION/CHECK Page 5001 Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Table 5001 - Check Schedules INSPECTION A A. Structure B. Joints C. Upper and Lower Attachments D. Rubstrip and Bumpers E. Workdecks and Workcounters F. Air Filters and Ventilation Ducts G. Mechanical (1) Slide Extractor (2) Turn Retainer (3) Door Assembly H. Electrical (1) Switches, Circuit Breakers and Fans (2) Wire Bundle Assemblies (3) Terminal Lugs, Connectors and Terminal Boards (4) Bulbs, Fluorescent tubes, cap, lenses and LED I. Plumbing J. Placards K. Refrigeration CHECK SCHEDULE B C D E
NOTE: Too much wear must be specied as any obvious deformation or deterioration of a part, which can make the equipment does not operate. If you are not sure about the serviceability of a part, the part must then be thought unserviceable. D. Procedure Subtask 25-36-03-220-001-A01 (1) Structure (a) Examine the structure of galley for scratches, cracks, holes and other damage. CAUTION: THE GALLEY MUST BE SHUT DOWN AND REMOVED FROM THE AIRCRAFT FOR SIGNS OF CRACKS OR HOLES IN THE PANELS. 1 2 3 To remove the galley from the aircraft (Ref. TASK-25-36-03-000-802-A01). To repair the panels (Ref. TASK-25-36-03-300-803-A01). To replace the panels, speak with Driessen engineering.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (b) (c) (d) (e) Make sure the decorative material is satisfactorily bonded. If damaged, (Ref. TASK-25-36-03300-805-A01) for repair procedure. Examine the galley for corrosion, especially milled or metal components and moist compartments. Examine trims, protective strips and kickstrips for attachment. Make sure the areas which are not under easy access in the galley are clean.
Subtask 25-36-03-220-002-A01 (2) Joints (a) (b) Make sure all screwed joints of the galley are satisfactorily attached. Tighten the loose screws and bolts. For correct torque values (Ref. TABLE-8001). Make sure all rivet joints are satisfactory. If rivets are loose, remove all rivets and replace.
Subtask 25-36-03-220-003-A01 (3) Upper and Lower Attachments (Ref. Fig. 1) (a) (b) (c) (d) (e) Examine upper and lower attachments for damage and satisfactorily attached. Examine upper and lower attachments for sign of vibrations. If these markings exist, replace the attachments. Examine carefully all attachment for corrosion. Floor ttings must be examined carefully. Replace if necessary. Examine oor seals between galley and aircraft oor. If seal is broken or deteriorated, replace it. Examine tie rods of upper attachments for easy movement. Tighten the bolts to its correct torque value, refer to ts and clearances (Ref. TASK-25-36-03-800-802-A01).
Subtask 25-36-03-220-004-A01 (4) Rubstrips, Slide Extractors and T-dividers (a) Examine all rubstrip and tee assembly for dents and nicks. NOTE: Rubstrips showing 50% wear must be replaced with serviceable pad. (b) Examine slide extractor cable for frays. Cable with frays are unacceptable and slide extractor must be replaced.
Subtask 25-36-03-220-005-A01 (5) Workdecks and Workcounters (a) Examine workdecks and workcounters for corrosion and awless sealing.
Subtask 25-36-03-220-006-A01 (6) Air Filters and Vents
WARNING: ALWAYS WEAR AIR FILTER MASK DURING THIS INSPECTION AND CHECK PROCEDURE. NOTE: Never wash the air lter. It must be replaced. (a) Examine air lters for dirt and dust collection.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (b) Examine air vents for dirt and dust collection. To clean the vents, do procedures as follows: 1 2 3 4 5 Unfasten the screws to remove the vent. Use compressed air to blow out collected dirt and dust. If dirt still exists, replace the vent. For easy replacement, cut the lter with 0.4 mm (0.016 in.) more length all around ventilation screen. Visually examine the duct and compartment for leaks. Examine the ducts for damage.
Subtask 25-36-03-220-007-A01 (7) Mechanical (a) Slide extractor 1 (b) Examine cables for frays. Replace slide extractor, if cable has frays.
Turn retainer 1 2 Rotate counter clockwise to examine the retainer. There must be no looseness when the retainer is turned. If it is loose, use a screwdriver to tighten.
(c)
Door/drawer assembly 1 2 3 Examine the doors/drawers for OPEN and CLOSE positions. Examine hinges, springs, extrusions and panel for damage. Do a operational check for slam and slide latches.
Subtask 25-36-03-210-001-A01 (8) Electrical (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) Make sure the mechanical functions of switches, circuit breakers and fans. Examine wires and electrical components for attachment, damage and overheating signs. Make sure all electrical connections for tightness and contact. Examine all connections for cleanliness. Examine the plugs and receptacles for looseness. Also examine for missing pins and contact sockets. Make sure terminal lugs for rm connection on wire ends. Examine connections on terminal boards and ground studs for corrosion. Examine soldered and crimped connections for security. Examine tension relief clamps on plugs and receptacles for security. Examine wires and inserts for insulation resistance. For procedures (Ref. SUBTASK-25-3603-750-001-A01). Do the dielectric test. For procedures(Ref. SUBTASK-25-36-03-750-001-A01).
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (l) Examine worklight lenses, area light lenses, cap and control lamps for cleanliness, damage and presence.
(m) Examine all bulbs and uorescent tubes in worklights, area lights and indicator lights. Subtask 25-36-03-210-002-A01 (9) Plumbing (a) (b) (c) (d) (e) Examine the plumbing system for leakage. Examine for worn out, cracked or deteriorated hoses or tubes. Examine tubes for obstruction with compressed air, or with water 5 psig (0.345 bar). Make sure valves and faucets for proper operation. Examine drain line for unobstructed ow.
Subtask 25-36-03-210-003-A01 (10) Placards (a) Examine placards for the sign of damages like scratches, worn outs, etc.
Subtask 25-36-03-210-004-A01 (11) Refrigeration (a) (b) (c) (d) Visually check for duct and compartment leaks. Check for ducting damage. Check chiller Installation and interface with ducts. Check temperature sensors.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 REPAIR TASK 25-36-03-300-801-A01 1. Repair No. 1 - Rivet Parts Repair A. Reason for the Job This task lets the user to repair the permitted parts. Except for those permitted repairs outlined below, the repair of a detailed part or component is not thought practical. The user thus make sure that the repaired parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the repair.
References NAME Disassembly
REFERENCE Page block 3001 C. Job Set-up None D. Procedure Subtask 25-36-03-390-001-A01 (1) Rivet Repair (a)
Permitted limitations on size of rivet holes, where rivets were drilled out on disassembly, are controlled by standard shop-practice use of oversize replacement rivets. NOTE: The initial design gives the minimum pitch and distances for rivets. This must be carefully monitored during repair.
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REPAIR Page 6001 Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-300-802-A01 2. Repair No. 2 - Weld Parts Repair A. Reason for the Job This task lets the user to repair the permitted parts. Except for those permitted repairs outlined below, the repair of a detailed part or component is not thought practical. The user thus make sure that the repaired parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the repair.
REFERENCE Page block 3001 C. Job Set-up None D. Procedure Subtask 25-36-03-310-001-A01 (1) Weld Repair
CAUTION: PREVENT CUTTING INTO METAL OF ADJACENT PARTS. (a) (b) (c) Do spot-facing to replace damaged spot or tack-weld parts, cut away spot or tack in the damaged part. Spot or tack-weld the replacement part to the not damaged part between old spots or tacks. Refer to specication MIL-W-6858 to do spot-welding with two or four spots at a minimum edge distance of 6.35 mm (0.25 in.).
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-300-803-A01 3. Repair No. 3 - Panel Repairs A. Reason for the Job This task lets the user to repair the permitted parts. Except for those permitted repairs outlined below, the repair of a detailed part or component is not thought practical. The user thus make sure that the repaired parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the repair.
REFERENCE Page block 3001 C. Job Set-up None D. Procedure Subtask 25-36-03-360-001-A01 (1) Damaged Honeycomb Panel Repair (a)
Repair procedure for damaged honeycomb panel when the damaged area is 152.4 mm (6 in.) or less, and the affected area is limited to the panel skin on one side plus the under lying core material. 1 2 Remove damaged skin and core material by cutting a round hole of 152.4 mm (6 in.) or less. Do not cut into the panel skin on the opposite side. Make a plug with the same material (nomex core, 1/8 cell with on both sides two plies phenolic resin impregnated woven glass cloth) and thickness by cutting the material to 3 mm (0.12 in.) smaller than the panel hole. Remove one side of the materials skin. Cold bond in place (plug with skin on damaged side of the panel), use Araldite AV 5308, Hardener HV 5309-1 (mixture 1:1). Put a mark of 63.5 mm (2.5 in.) border around the plug (on damaged side of the panel). When applicable remove decor or paint and decor-adhesive in marked area. Do not damage the panel skin. Abrade the marked area lightly but tightly. Use No. 400 grit abrasive paper. Make a round anodized aluminum cover sheet 127 mm (5 in.) larger in diameter than the plug. Moist a cloth with methylated spirit solvent and clean the marked area and cover sheet clean. Use a clean dry cloth to dry the surfaces.
3 4 5 6 7 8 9
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 NOTE: Do not let the solvent to dryness. CAUTION: USE SOLVENT ONLY IN WELL-VENTILATED AREAS. DO NOT EAT, DRINK OR SMOKE WHILE WORKING. KEEP AWAY FROM IGNITION SOURCES. 10 11 12 13 14 Apply the adhesive on panel and cover sheet. Use a trowel with knurled edge. Cold bond cover sheet in marked area. Use Araldite AV 5308, Hardener HV 5309-1 (mixture 1:1) Seal the edges. Use Araldite AV 5308, Hardener HV 5309-1 (mixture 1:1) Use clamps or vacuum to hold the cover sheet in position. Curing time is 14 hours at 23 C (73.4 F). When the undamaged side of the panel is opened to the cabin interior and the total opened surface area of the repairs on the unit more than 610 sq mm (2 sq ft), an aluminum sheet on this side of the panel is necessary as well.
Subtask 25-36-03-360-002-A01 (2) Damaged Honeycomb Panel Repair Procedure (a) Repair procedure for damaged honeycomb panel when the damaged area is 152.4 mm (6 in.) in diameter or less, and both sides of the panel skin are affected. 1 2 3 4 5 6 7 8 9 Cut a round hole up to 152.4 mm (6 in.) through the panel removing the damaged panel material. Make a plug with the same material and thickness by cutting the material to 3 mm (0.12 in.) smaller than the panel hole. Cold bond in place, use Araldite AV 5308, Hardener HV 5309-1 (mixture 1:1). Sand smooth. Put a mark of 63.5 mm (2.5 in.) border around the plug on both sides of the panel. When applicable remove decor or paint and decor-adhesive in marked area. Do not damage the panel skin. Abrade the marked area lightly but tightly. Use No. 400 grit abrasive paper. Make two round anodized aluminum cover sheets of 127 mm (5 in.) larger in diameter than the plug. Moisten a cloth with methylated spirit solvent, and clean the marked area and cover sheets clean. Use a clean dry cloth to dry surfaces. NOTE: Do not let the solvent to dryness. CAUTION: USE SOLVENT ONLY IN WELL-VENTILATED AREAS. DO NOT EAT, DRINK OR SMOKE WHILE WORKING. KEEP AWAY FROM IGNITION SOURCES. 10 11 12 13 Apply the adhesive on panel and cover sheets. Use a trowel with knurled edge. Cold bond cover sheet in marked area. Use Araldite AV 5308, Hardener HV5309-1 (mixture 1:1). Seal the edges. Use Araldite AV 5308, Hardener HV 5309-1 (mixture 1:1). Use clamps or vacuum to hold the cover sheet in place. Curing time is 14 hours at 23 C (73.4 F). REPAIR Page 6004 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Subtask 25-36-03-360-003-A01 (3) Inserts Replacement Repair (a) This procedure gives instructions to replace bonded inserts in honeycomb panels. 1 2 3 4 Remove damaged insert by warming insert with a heat gun until adhesive weakens. Remove damaged insert by manually pulling with small hand pliers. Remove paper backing from SLT600-Shu tab and press insert on to tab, aligning holes in tab with holes in insert. Place Shur-tab insert assembly in installation hole. Apply sufcient force to insure that the tab will bond to face of panel. Use Araldite AV 5308 and Hardener HV 5309-1 (mixture 1:1) to bond the insert. Curing time is 14 hours at 23 C (73.4 F). Table 6001 - Panel Repair Materials MATERIAL Panel Cover material IDENTIFICATION Same as damaged panel (honeycomb sandwich panel) Sheet AL 5754 (AlMg3) 0.6 mm (0.024 in.) thick, anodized Systems Methylated spirit. Araldite Adhesive AV 5308, Hardener HV 5309-1 ratio 1:1 SOURCE Driessen Aircraft Interior Systems Driessen Aircraft Interior Any approved source Vantico or other approved sources Sortieweg 39 6219 NT Maastricht (31)(0)24670611 Lincoln Inc. or other approved sources 851 West 18th Street Costa Mesa, CA 92627-4410 949 - 6508106
Solvent Bonding material
Edge ller
Part A Part B ratio part A 100:part B 50
The following repair kits are available at Driessen Holland: Repair kit for repairs to a maximum of 50.8 mm (2 in.) diameter, Driessen PN 290509-11 Repair kit for repairs to a maximum of 101.6 mm (4 in.) diameter, Driessen PN 290509-21 Repair kit for repairs to a maximum of 152.4 mm (6 in.) diameter, Driessen PN 290509-31
All kits have a honeycomb sandwich panel plug and two aluminum cover sheets. Refer to part number of the damaged unit and thickness of the panel which has to be repaired when you order a repair kit. REPAIR Page 6005 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-300-804-A01 4. Repair No. 4 - Decorative Area Repairs A. Reason for the Job This task lets the user to repair the permitted parts. Except for those permitted repairs outlined below, the repair of a detailed part or component is not thought practical. The user thus make sure that the repaired parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the repair.
REFERENCE Page block 3001 C. Job Set-up None D. Procedure Subtask 25-36-03-380-001-A01 (1) Metal Decor Panels Repair (a) (b) (c)
Dents in metal decor panels can be removed by planishing, lightly with a small hammer from reverse side. Plastic-coated panels must be worked against an anvil covered with a thin sheet of rubber or equivalent material to keep decorative surface appearance. Painted panels can necessary more nishing by repainting.
Subtask 25-36-03-380-002-A01 (2) Stainless Steel Surfaces Repair (a) Stainless steel surfaces can also have dents removed by planishing lightly with a small hammer from reverse side. However, access to dent must be available by removing a section of backing panel. Cut out a small area of panel back skin and core opposite the dent, leaving inner panel intact and then, after removing the dent, ll the cutout by plugging. Renish stainless steel surface, if necessary.
(b) (c)
Subtask 25-36-03-380-003-A01 (3) Satin-Brushed Stainless Steel Surfaces Repair (a) Scratches or other discontinuities in satin-brushed stainless steel surfaces or other satinbrushed metal surfaces can be removed by nishing and blending. Use a moderate grade satin nishing abrasive and work in same direction as initial grain. REPAIR Page 6006 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Subtask 25-36-03-380-004-A01 (4) Painted Surfaces Repair (a) Damage to the painted surfaces are repaired by the procedure that follows: 1 2 3 4 If substrate is damaged, ll objectionable scratches, gouges, etc., with lling compound, sanding smooth after it sets up (Ref. TABLE-6002). Remove all loosely adhering paint or particles of substrate by sanding around damaged area. Use a ne grade of abrasive paper or cloth, or feather in edges of existing coating. Clean area with cleaning solvent and dry with a clean cloth before solvent dries. Spray applicable coating, refer applicable trim and nish drawing to touch-up the area. If considerable metal has been bared by damage or feathering procedures, it is advisable to rst apply a protective coating of primer. Decorative metal surfaces that have a peened, or non-directional, nish initially can have blemishes removed as follows: a If cracks occur in welds or other areas of metal components such that only the appearance of hygienic features of unit are affected, the cracks must be stopped by drilling small holes, approximately 1 mm (0.04 in.), at the ends. Remove protective coating on the full area that will be painted. Wipe with cleaning solvent and mask the adjacent surfaces to prevent from overspray. Fill cracks and stop holes, or scratches with lling compound. Sand smooth with ne paper after compound sets. Wipe with cleaning solvent to remove sanding residue and handling soil and nish by spraying touch-up coating. Let to dry for one hour at room temperature. Again apply protective coating where removed.
b c d e
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-300-805-A01 5. Repair No. 5 - Decorative Materials Replacement A. Reason for the Job This task lets the user to repair the permissible parts. Except for those permissible repairs outlined below, the repair of a detailed part or component is not thought practical. The user thus make sure that the repaired parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the repair.
REFERENCE Page block 3001 C. Job Set-up None D. Procedure Subtask 25-36-03-380-005-A01 (1)
Damaged Decorative Laminates Removal (a) (b) (c) (d) (e) Remove all sealant on edges adjacent to metal extrusion. If extrusion is overlapping the adhesive laminate, cut laminate along edge of extrusion. Use a heat gun to warm-up decorative laminates to weaken adhesive. Start from one corner, peel decorative away from the wall. Remove remains of adhesive with adhesive remover, when all decorative is removed (Ref. TABLE-6002). Let dry for 24 hours.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Table 6002 - Decor Area Repair Materials MATERIAL PART NUMBER MANUFACTURER or other approved sources Vantico Sortieweg 39 6219 NT Maastricht (31)(0)24670611 Kox en zn. Postbus 261 1520 AG Wormerveer (31)(0)756287651 414-12 Alexit hardener 402 Alexit thinner 62 Alexit - FST 404-12 Alexit hardener 400 Alexit thinner 62 904-47 Bostik 14-554-3 Mankiewicz Gerbr. and Co. Georg Wilhelm str. 189 21107 Hamburg 00-49 40751030 Mankiewicz Gerbr. and Co. Ratio 15:1 20:1 REMARKS
STRUCTURE ADHESIVE Araldite Adhesive AV 5308 Hardener HV 5309-1 FILLER Polysoft
Ratio 1:1
PAINT A. Primer B. Hardener C. Thinner A. Paint B. Hardener C. Thinner DECOR Adhesive remover Bonding lm
Mankiewicz Gerbr. and Co. Bostik B.V. Ravenswade 54 bis Nieuwegein (31) (0) 30 2885511 National Starch and Chemical P.O. Box 13 7200 AA Zutphen (31)(0) 575 582500
Adhesive improver Solvent
Bondmaster adhesive 7804 Bondmaster Solvent G 5021E
Subtask 25-36-03-110-004-A01 (2) Wall Cleaning (a) (b) (c) Clean the wall before installing decorative material. Moist a cloth with ethyl alcohol or acetone and wipe surface clean. Do not touch the cleaned surfaces with bare hands.
Subtask 25-36-03-110-005-A01 (3) Filler Material Application (Ref. TABLE-6002) (a) Clean small localized areas, such as voids and gaps (Ref. SUBTASK-25-36-03-110-004A01). REPAIR Page 6009 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (b) (c) (d) Apply ller material and smooth. Let ller to dry and sand ush with panel or desired. Clean the surface (Ref. SUBTASK-25-36-03-110-004-A01).
Subtask 25-36-03-350-001-A01 (4) Adhesive (a) Selection of adhesives - depending on the covering material: 1 2 (b) Adhesive improver is to be used when covering material is self-adhesive. Adhesive improver and bonding lm are to be used when covering material is not selfadhesive.
Apply adhesive improver by the procedure that follows: 1 2 3 4 5 Clean surface to be bonded (Ref. SUBTASK-25-36-03-110-004-A01). Thin the improver with solvent (ratio about 2 solvent : 1 improver). Apply a thin, smooth coat of improver with a spray gun, roller or brush to the surface to be covered. Prevent a heavy layer of improver to prevent stringing and clumping. A thin coat is more good than a thick layer. Let improver to dry for 10 25 minutes. Apply covering material (Ref. SUBTASK-25-36-03-350-002-A01).
(c)
Apply the bonding lm by the procedure that follows: 1 2 Clean the surface (Ref. SUBTASK-25-36-03-110-004-A01). Cut the lm with scissors, knife or other sharp blade as follows: a b 3 Refer to engineering drawings for correct panel dimensions. Add 100 mm (4 in.) to height and width dimensions.
Film application methods a Direct method - lm smaller than 300 sq mm (1 sq ft) 1 2 3 b Remove the full liner from the adhesive side of the lm. Align the lm and press one edge to the surface with nger pressure. With a plastic applicator, squeeze the remaining unapplied part, use tight, overlapping strokes.
Scored line method - lm smaller than 1220 sq mm (4 sq ft) 1 2 3 Keep the liner on the lm, expose 25 50 mm (1 2 in.) area of adhesive and register the lm along the registry line. Press adhesive to the surface with nger pressure. Squeeze the lm into place with rm, overlapping strokes across the width of the lm, while removing the remainder of the liner a few inches at a time to prevent pre-adhesion.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 c Top horizontal hinge method - lm larger than 1220 sq mm (4 sq ft) 1 2 3 4 Keep the liner on the lm. Tape the lm into position with small pieces of masking tape. Apply 50 75 mm (2 3 in.) tape above the top edge to serve as a hinge. Make a cut about half-way through the tape hinge at two ends. Lift the lm up along the top hinge and peel the liner back a few inches at a time, while squeezing the surface with rm, overlapping strokes, starting at the top center and working down and outward toward each edge. Hold the lm away from the surface with one hand and let the adhesive to touch only as pressure is applied. Again squeeze the edges.
5 6 d
Center hinge method - lm larger than 1220 sq mm (4 sq ft) 1 2 Keep the liner on the lm. Tape the lm into position with small pieces of masking tape. Apply 25 50 mm (1 2 in.) tape hinge through the center of the lm, either vertically or horizontally. Fold half of the lm back on the hinge, peel the liner off of the lm (back to the tape hinge), cut the liner along the hinge and discard. Fold the lm back down and squeeze the surface starting at the center from the page hinge and work outward and away from the tape hinge, use rm, overlapping strokes. Hold away from the surface with one hand and allow the adhesive touch only as pressure is applied. Remove the tape hinge. Fold over half of the lm, remove the liner and apply as above.
3 4
5 6 7 e f g
If air bubbles are present after application of bonding lm, puncture the lm at one end with a sharp needle point tool. Press out entrapped air toward puncture. Remove polyethylene release liner. Apply covering material (Ref. SUBTASK-25-36-03-350-002-A01).
Subtask 25-36-03-350-002-A01 (5) Decorative Covering Material Application (a) (b) (c) For the applicable location of decorative materials used on this unit, (Ref. Fig. 6001). Align covering material and press one edge to the lm with plastic applicator. Squeeze the remaining unapplied part, use lm, overlapping strokes.
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Trim and Finish Figure 6001/GRAPHIC 25-36-03-991-005-A01
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-300-806-A01 6. Repair No. 6 - Corrosion Removal A. Reason for the Job This task lets the user to repair the permitted parts. Except for those permitted repairs outlined below, the repair of a detailed part or component is not thought practical. The user thus make sure that the repaired parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the repair.
REFERENCE Page block 3001 C. Job Set-up None D. Procedure Subtask 25-36-03-350-003-A01 (1)
Door Assemblies and Panels Corrosion Removal (a) (b) (c) (d) Use a cloth saturated in a liquid solution of 50% distilled water and 50% corrosion removing compound. Flush the treated area fully with warm, potable water. Dry with compressed air. Make a mark of all areas cleaned for corrosion in this manner for inspection as per the check procedure (Ref. SUBTASK-25-36-03-220-007-A01).
Subtask 25-36-03-350-004-A01 (2) Non-appearance Surfaces Corrosion Removal (a) Corrosion of non-appearance surfaces such as hardware associated with panels can be stopped by cleaning and applying a protective coating. 1 2 3 Clean affected area with cleaning solvent by hand wiping to remove organic soil. Remove corrosion products by brushing with a non-metallic bristle brush or by sanding. Rinse with clean water and dry fully. Apply protective coating to affected areas.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-300-807-A01 7. Repair No. 7 - Placard Replacement A. Reason for the Job This task lets the user to repair the permitted parts. Except for those permitted repairs outlined below, the repair of a detailed part or component is not thought practical. The user thus make sure that the repaired parts are in good condition. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the repair.
REFERENCE Page block 3001 C. Job Set-up None D. Procedure Subtask 25-36-03-350-005-A01 (1) Placard Replacement
NOTE: The approximate location of each placard is to be shown on the placard installation or nal assembly drawing, unless specied by other documents. (a) (b) (c) (d) (e) (f) Proper bonding strength of pressure sensitive placards can only be get on clean surfaces. All contaminants must be removed by cleaning area with proper cleaner. Care must be taken to make sure compatibility of cleaner and material to be cleaned. Metals such as stainless steel and aluminum must be degreased and abraded if necessary, to give a smooth clean surface. Placards with adhesive must be applied at temperatures between 10 60 C (60 110 F). To install placards with pressure-sensitive adhesive, remove backing paper and apply rm same pressure. Rivets necessary for placards must be installed, use blind rivets.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 ASSEMBLY TASK 25-36-03-400-801-A01 1. Galley System Assembly A. General TBD
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ASSEMBLY Page 7001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 FITS AND CLEARANCES TASK 25-36-03-800-802-A01 1. Torque Values A. General The torque values used are in accordance with the usual standard practices (Ref. TABLE-8001). Table 8001 - Torque Values TENSION TORQUE (in lbs) 12 15 15 17 20 25 65 90 130 180 220 360 TENSION TORQUE (in Nm) 1.4 1.7 1.7 1.9 2.3 2.8 7.3 10.2 14.7 20.3 24.9 40.7 THREAD SIZE 6 32 8 32 10 32 28 5/16 24 3/8 24
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FITS AND CLEARANCES Page 8001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 SPECIAL TOOLS, FIXTURES AND EQUIPMENT TASK 25-36-03-900-801-01 1. Special Tools, Fixtures and Equipment A. General Not applicable.
SPECIAL TOOLS, FIXTURES AND EQUIPMENT Page 9001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 SPECIAL PROCEDURES TASK 25-36-03-900-802-01 1. Special Procedures A. General Not applicable.
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SPECIAL PROCEDURES Page 11001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 REMOVAL TASK 25-36-03-000-802-A01 1. Removal A. General TBD
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REMOVAL Page 12001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 INSTALLATION TASK 25-36-03-400-802-A01 1. Installation A. General TBD
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INSTALLATION Page 13001 Jul 4/08
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Page Blank Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 SERVICING TASK 25-36-03-610-801-A01 1. Servicing A. Reason for the Job This procedure is usually done by the ight attendants while the aircraft is in-service. B. Job Set-up Information (1) Tools, Equipments and Consumables (a) (2) No special tools, equipments or consumables are necessary for the servicing.
References NAME Cleaning
REFERENCE Page block 4001 C. Job Set-up None D. Procedure Subtask 25-36-03-610-001-A01 (1) In-service Cleaning
CAUTION: CLEANING CLOTHS ARE TO BE MOIST NOT WET, EXCESS WATER CAN DAMAGE ELECTRICAL COMPONENTS. NOTE: This procedure is normally performed by the ight attendants while the aircraft is in-service. For recommended cleaning agents and materials (Ref. TABLE-4001). (a) (b) (c) Clean all spilled liquid immediately with a clean, soft cloth. Clean all exposed galley surfaces with a clean, moist cloth, including the inside compartments and all working surfaces. Clean all inserts, correctly stow all waste materials and clean all work areas.
Subtask 25-36-03-890-001-A01 (2) Field Maintenance
CAUTION: CLEANING CLOTHS ARE TO BE MOIST, NOT WET, EXCESS WATER CAN DAMAGE ELECTRICAL COMPONENTS. NOTE: After each ight, ground crew maintenance must include these steps for cleaning the galley. For recommended cleaning agents and materials (Ref. TABLE-4001). (a) (b) (c) (d) Remove all perishable items from the galley. Clean all the surfaces of galley. Use a mild disinfecting detergent and a clean, soft cloth. Carefully clean food handling surfaces or areas, such as work counters, coffee makers, etc. SERVICING Page 14001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (e) Vacuum the galley.
Subtask 25-36-03-890-002-A01 (3) Periodic Maintenance (a) Performance of this procedure is recommended no less than on a 1500 ight hours basis. All the steps for in-service cleaning and eld maintenance must be done before the instructions which follow are executed (Ref. SUBTASK-25-36-03-610-001-A01) and (Ref. SUBTASK-2536-03-890-001-A01). Clean in and around the beverage makers as follows: WARNING: PREVENT ELECTRIC SHOCK FROM INTERRUPTION IN THE FLOW OF ELECTRICITY TO THE INSERT, AT THE CIRCUIT BREAKER. 1 2 3 Switch OFF the electrical circuit, supplying power to the beverage maker. Disengage and slide out beverage maker from coffee maker rail. Continue to disassemble beverage maker rails from the sump assembly by removing hardware in four places (screws, washers and spacers). Keep all hardware for reinstallation of rail after completion of cleaning. NOTE: It is not necessary to fully remove the coffee maker rails from compartment in order to clean underneath. plumbing lines and electrical connections located at the rear of the rails can be left intact. WARNING: PROTECTIVE EYE SHIELDS OR GOGGLES ARE TO BE WORN WHEN CLEANING WITH COMPRESSED AIR. CONTAMINATION AND/OR HIGH PRESSURE AIR CAN CAUSE SERIOUS EYE INJURY. CAUTION: SMALL PARTS CAN EASILY BE DAMAGED BY HOLDING THE COMPRESSED AIRJET NOZZLE TOO CLOSE. USE BRUSHES CAREFULLY ON EASILY DAMAGED PARTS. 4 5 Use compressed air to blow away dust from small recesses, holes and enclosures. Lift the beverage maker rail and increase ample access to the sump area underneath. Remove hardware securing sump screen and clean/clear out visible unwanted material.
(b)
WARNING: PREVENT BREATHING THE VAPORS OR FUMES FROM CLEANING SOLVENT. GOGGLES, GLOVES, A MASK AND PROTECTIVE CLOTHING ARE TO BE WORN TO PREVENT IRRITATION FROM LONG TOUCH WITH CLEANING AGENTS. CLOTHES MUST BENGED IF SOLVENTS SPILLED ON THEM. CAUTION: DO NOT LET CLEANING FLUIDS TO RUN INTO CONNECTORS, SWITCHES, TUBING COVERING WIRES OR ELECTRIC PANELS. 6 Remove stains from all surfaces of the sump with an applicable cleaning solvent. The solvent must then be removed, use a soft, lint-free cloth soaked in Rho-clene. Stubborn residue can be removed with Kleenol-30. Use abrasive cleaning agents, scouring powders (ammoniated or chlorinated) to remove hard soil and non-metallic scouring pads used with care, so as to prevent damaging of anodized surfaces. Clean all surfaces dry with a clean, lint free cloth. Re-install sump screens and beverage makers, use previously removed screws. Do all Check procedures at this time.
8 9
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SERVICING Page 14002 Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (c) Clean the metal parts by the procedure that follows: 1 2 Remove dirt, grease and oil from metal structural parts with a clean cloth saturated with toluene, benzene or xylene cleaning solvent. Clean all dry surfaces with a clean, lint free cloth and to remove solvent lm or residue. Re-install oven, use previously removed hardware.
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SERVICING Page 14003 Jul 4/08
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Page Blank Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 STORAGE TASK 25-36-03-550-801-A01 1. Storage after Assembly A. Reason for the Job The containers and procedures that follow are to be used for transport and to keep the galley in storage. B. Job Set-up Information (1) Packing Materials NOTE: Alternatives can be used. Material Bag, polythene Container, plywood Cushion material (Corrugated paper) Paper, SBI (Sodium Benelate Impregnated) C. Job Set-up None D. Procedure Subtask 25-36-03-530-001-A01 (1) Packing and Storage Procedures (a) (b) (c) (d) The galley assembly must be corrosion resistant and thus no special preservation is necessary. Put the assembly in waterproof wrapping paper or plastic cover. Use tape to secure wrapping paper or cover. Identify unit by part number, serial number and date of maintenance or overhaul on a tag or in a convenient location on wrapper. Keep in a cool, dry place away from direct sunlight and heat. Specication Supplier Local supply Local supply Local supply Local supply
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STORAGE Page 15001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 REWORK TASK 25-36-03-900-803-01 1. Rework A. General Not applicable.
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REWORK Page 16001 Jul 4/08
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Page Blank Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 ILLUSTRATED PARTS LIST TASK 25-36-03-950-801-A01 1. Introduction A. Purpose (1) The Illustrated Part List (IPL) contains the illustrations and the parts lists for the assembly given in the leading particulars. The parts lists give the items that can be disassembled, repaired or replaced, and assembled.
B.
How to Use this Section NOTE: The data that follows are included as necessary in the IPL. (1) Figure and item column (a) (b) (c) (d) The gure number at the top left of the column relates the parts list to the illustration. The end item number 1A is applicable to the end item that is shown in the illustration. The items that are changed are shown immediately after the end item (1B, 1C etc.). A hyphen (-) before an item number shows that the item is not shown on the illustration. The item number sequence is in, as far as possible, the disassembly sequence of the end item. The sequence is in steps of more than one to let, when necessary, more items to be included. Alpha sufxes, A thru Z (except I and O), are used when it is necessary to add more items to show: 1 2 3 4 (f) (g) Special-to-type items. Service Bulletin modications. Conguration differences. Parts that have been made better (non-Service Bulletin).
(e)
Alpha sufxes to the item numbers are not usually shown on the illustration. This does not apply when the shape and the location of the alpha item are not the same as the basic item. Parts that make a select-from-range group have one (not shown item number) after the other. This does not apply to the supplied conguration, or the part number of the smallest part which is shown.
(2)
Part number column (a) The part number column contains the part number which can be: 1 2 3 A part number that is standard such as AGS, MS, AN, NAS etc. The manufacturers part number or their suppliers part number. Trade marks used by Driessen Aircraft Galley System under license are Driessen and Driessen logo.
(3)
Airline part number column (a) This empty column is given for use by the equipment operator.
(4)
Nomenclature column (a) The parts are in a sequence which shows that how one part relates to the other part: IPL Page 10001 Jul 4/08
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 1234567 Assembly or installation assembly (RF) number (End Item) Attaching parts for assembly or installation of RF assembly *** .Detail parts for assembly .Subassembly (secondary to lead item) .Attaching parts for subassembly *** ..Detail parts for subassembly ..Sub-subassembly (secondary to subassembly) ..Attaching parts for sub-subassembly *** ...Detail parts for sub-subassembly NOTE: The words or installation assembly (RF) number is used to identify a nonprocurable group (installation) of parts that does not make a known assembly. (b) (c) (d) (e) The suppliers part number is given in the nomenclature column together with his vendor code. The materials from which the part is made and its dimensions are usually specied together with the suppliers vendor code. Parts which require special handling are identied. For example, electrostatic discharge sensitive electronic components are identied with ESDS. Parts replacement data 1 The parts that are interchangeable are identied in the nomenclature column of the parts list. The abbreviations used to show those parts that are, or are not, interchangeable are: (f) OPT. The part is optional to and is interchangeable with other parts in the same item number group (or other item number if designated) SUPSD BY The part is replaced by and is not interchangeable with the item number given SUPSDS The part replaces and is not interchangeable with the item number given REPLD BY The part is replaced by and is interchangeable with the item number given REPLS The part replaces and is interchangeable with the item number given
Service bulletin incorporation 1 (PRE-SB XXXX) in the nomenclature column identies the initial conguration. (POSTSB XXXX) identies the assemblies and the parts after the Service Bulletin modication has been completed.
(5)
Effectivity column (a) Parts identied with an effectivity code (A, B, C etc.) must be used with parts having the same or no effectivity code.
(6)
Units per assembly column (a) The quantity specied is the quantity of a specic-item-numbered part necessary to assemble (as applicable) its subsequent higher: Sub-subassembly Subassembly
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IPL Page 10002 Jul 4/08
COMPONENT MAINTENANCE MANUAL PART No. 601307-1 (b) (c) Assembly or installation level
AR is used for bulk items, and select-from-range parts that are not shown on the illustration. The quantity is that necessary for the assembly. RF shows the part is included in the illustrated parts list for identication only.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 TASK 25-36-03-970-801-A01 2. Numerical Index A. Numerical Index Table PART NUMBER AIRLINE STOCK NUMBER FIGURE ITEM TOTAL REQ.
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Suppliers Name and Code List All part numbers in the "Part Number" column are those of AMI, a government or National Aerospace Standard, or a vendor. Vendor parts used in this parts list are listed by manufacturer's part number and are identied by a ve digit code prexed with the letter V. This code comes into view in parentheses following the part description in the nomenclature column. Vendor codes are in accordance with the federal supply code for manufacturer's cataloguing handbook H-4-1. Vendor codes used in this parts list are given below: Vendor Code VC5307 Vendor Names and Addresses INNOVINT AIRCRAFT INTERIOR EINRICHTUNGS GMBH HOLZMUEHLENSTR, 84-86 D22041 HAMBURG - GERMANY RYAN HERCO 16424 ISHIDA AVE GARDENA, CA 90248 NMC FASTENING SYSTEMS DIVISION OF NYLON MOLDING 1617 S. CALIFORNIA AVE. MONROVIA, CA 91016-4621 RAYCHEM CORP. 300 CONSTITUTION DR. MENLO PARK, CA 94025-1111 CAMLOC FASTENER CORP. LOS ANGELES, CA EVERPURE INC. V08756 EVERPURE INC. 660 N. BLACKHAWK DR. WESTMONT, IL 60559-1116 WHITEY CO. 318 BISHOP RD. HIGHLANDS HEIGHTS, OH 44143 BRUCE INDUSTRIES INC. 101 EVANS AVE. DAYTON, NV 89403 FLAME ENTERPRISES, INC. 20945 OSBORNE ST. CANOGA PARK, CA 91304-1847 OETIKER INC. 71-77 OKNER PKWY LIVINGSTON, NJ 07039 MARATHON SPECIAL PROD. 13300 VAN CAMP RD. BOWLING GREEN , OH 43402 SABRE INDUSTRIES INC. 120 W. PROVIDENCIA AVE. BURBANK, CA 91502 GEOMETRICAL STRUCTURES 26670 CAWSTON AVE. HEMET, CA 92343 SYLVANIA ELECTRIC PRODS. SEMICONDUCTOR DIV. HILLSBORO, NH 03244
VOUEP1
V03296
V06090
V08733
V12623
V17023
V2V320
V25281
V26405
V27045
V27998
V28107
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Vendor Code V3A054 Vendor Names and Addresses MC MASTER-CARR 9630 NORWALK BLVD. SANTA FE SPRINGS, CA 90670 AIR COLD SUPPLY 141 W. 23RD ST. LOS ANGELES, CA 90007 SEALTH AEROMARINE 16001 MILLCREEK BLVD., SE MILLCREEK, WA 98012 TYEE AIRCRAFT INC. 3008 100TH ST. SW EVERETT, WA 98204 HARPER ENGINEERING CO. 200 S. TOBIN ST. RENTON, WA 98055 BURBANK AIRCRAFT SUPPLY 10671 LANARK ST. SUN VALLEY, CA 91352-4033 SKYLOCK INDUSTRIES, INC. 904 S. ALTA VISTA AVE. MONROVIA, CA 91016-3318 ACTRON MFG INC. 1841 RAILROAD ST. CORONA, CA 91720 THOMAS & BETTS 1001 FRONTIER RD. BRIDGEWATER, NJ 08807 YOUNG ENGINEERS INC. P.O. BOX 278 LAKE FORREST, CA 92630-0278 PROMPTUS ELECTRONIC 520 HOMESTEAD AVE. MOUNT VERNON, NY 10550 ZEVCO INC. 22982 ALCALDE DR., SUITE 101 COONER MFG. CO. 9186 INDEPENDENCE AVE. CHATSWORTH, CA 91311 ITT CANON DIV. 666 E. DYER RD. SANTA ANA, CA 92702 CORY COMPONENTS INC. CORY COMPONENTS INC. 350 HAMPTON DR. VENICE, CA 90291 DIALIGHT CORP. 203 HARRISON PL. BROOKLYN, NY 11237
V3D883
V31845
V34742
V34941
V5N982
V51941
V52607
V56501
V56958
V57177
V62701
V63794
V71468
V71771
V72619
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 Vendor Code V76188 Vendor Names and Addresses CONTROL DESIGN SUPPLY 1168 KNOLLWOOD CIR. ANAHEIM, CA 92801 MECHANICAL PRODUCTS 1824 RIVER ST. P.O. BOX 729 SYLVANIA MINIATURE LIGHTING PROD. W. MAIN ST. CALIFORNIA FILTRATION PROD. 14480 HOOVER ST. WESTMINSTER, CA 92683 DAY RAY PRODUCTS 1133 MISSION ST. SO. PASADENA, CA 91030-3211 LEE SPRINGS CO. 1462 62ND ST. BROOKLYN, NY 11219 BOBRICK WASHROOM EQUIP. 11611 HART ST. N. HOLLYWOOD, CA 91605-5802 AEROWORKS 2727 S. CRODDY WAY SANTA ANA CA. 92704
V76374
V8F937
V8Z509
V82255
V84830
V89488
V4001
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Final Assembly Figure 1/GRAPHIC 25-36-03-991-006-A01
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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 FIG.ITEM 1 1A AIRLINE PART NUMBER EFF CODE (VH1D67) A UNITS PER ASSY RF
PART NUMBER 610307-1
NOMENCLATURE FINAL ASSEMBLY
25-36-03
25-36-03
Page 10010 Jul 4/08

Component Maintenance Manual With Illustrated Parts List: Part Number 601307-1

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Component Maintenance Manual With Illustrated Parts List: Part Number 601307-1

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DRIESSEN AEROSPACE SYSTEMS, BV DE STEK 1 1771 SP, WIERINGERWERF HOLLAND TEL: +31 227 606 162 FAX: +31

227 606 150 FSCM CODE: VH1D67

COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

GALLEY G1 PART NUMBER 601307-1

COMPONENT MAINTENANCE MANUAL PART No. 601307-1

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ISSUE DATE July 04/08

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TEMP REV No.

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COMPONENT MAINTENANCE MANUAL PART No. 601307-1 SERVICE BULLETIN LIST

INCLUDED DATE OF IN REVISION INCORPORATION

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DESCRIPTION AND OPERATION

TESTING AND FAULT ISOLATION

SCHEMATICS AND WIRING DIAGRAMS

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DESCRIPTION AND OPERATION 1. 2. 3. Description Operation Galley Specications 2 18 19

Galley System Fault Isolation A. Fault Isolation

DISASSEMBLY 1. Disassembly 3001

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Repair No. 2 - Weld Parts Repair A. Weld Repair

Repair No. 7 - Placard Replacement A. Placard Replacement

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FITS AND CLEARANCES 1. Torque Values 8001

SPECIAL PROCEDURES 1. Special Procedures 11001

REMOVAL 1. Removal 12001

INSTALLATION 1. Installation 13001

ILLUSTRATED PARTS LIST 1. 2. Introduction Numerical Index 10001 10004

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We veried the disassembly, testing and assembly procedures by actual performance.

(2) (3) (4) (5)

INTRODUCTION Page 1 Jul 4/08

INTRODUCTION Page 4 Jul 4/08

DESCRIPTION AND OPERATION Page 1 Jul 4/08

DESCRIPTION AND OPERATION Page 2 Jul 4/08

Chillers Work lights

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COMPONENT MAINTENANCE MANUAL PART No. 601307-1

General Arrangement (Sheet 1 of 9) Figure 1/GRAPHIC 25-36-03-991-001-A01

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COMPONENT MAINTENANCE MANUAL PART No. 601307-1

COMPONENT MAINTENANCE MANUAL PART No. 601307-1

General Arrangement (Sheet 3 of 9) Figure 1/GRAPHIC 25-36-03-991-001-A01

DESCRIPTION AND OPERATION Page 7 Jul 4/08

COMPONENT MAINTENANCE MANUAL PART No. 601307-1