1099L CMM 25-05-04

SELL manual
SELL GMBH 35745 HERBORN - GERMANY
COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L
GALLEY SYSTEM PN 1099L00A00000
ORIGINAL ISSUE NOV 29/07
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RECORD OF REVISIONS REV.NO. ISSUE DATE DATE INSERTED BY REV.NO. ISSUE DATE DATE INSERTED BY
RETAIN THIS RECORD IN THE FRONT OF THE MANUAL ON RECEIPT OF REVISIONS, INSERT REVISED PAGES IN THE MANUAL AND ENTER REVISION NUMBER, ISSUE DATE, DATE INSERTED AND INITIALS.
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SERVICE BULLETIN LIST
Service Bulletin
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Service Bulletin
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RECORD OF REVISIONS R/R 1 NOV 29/07 R/R 2 NOV 29/07 RECORD OF TEMPORARY REVISIONS RTR 1 NOV 29/07 RTR 2 NOV 29/07 SERVICE BULLETIN LIST SBL 1 NOV 29/07 SBL 2 NOV 29/07 LIST OF EFFECTIVE PAGES LEP 1 NOV 29/07 LEP 2 NOV 29/07 LEP 3 NOV 29/07 LEP 4 NOV 29/07 TABLE OF CONTENTS T/C 1 NOV 29/07 T/C 2 NOV 29/07 DESCRIPTION AND OPERATION 1 NOV 29/07 2 NOV 29/07 3 NOV 29/07 4 NOV 29/07 5 NOV 29/07 6 NOV 29/07 7 NOV 29/07 8 NOV 29/07 9 NOV 29/07 10 NOV 29/07 11 NOV 29/07 12 NOV 29/07 13 NOV 29/07 14 NOV 29/07 15 NOV 29/07 16 NOV 29/07
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LIST OF EFFECTIVE PAGES PAGE DATE 198.48 198.49 198.50 198.51 198.52 198.53/198.54 198.55 198.56 DISASSEMBLY 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07
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PAGE 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 CLEANING 401 402 403 404 405 406 CHECK 501 502 503 504 505 506 507 508 REPAIR 601 602 603 604 605 606
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LIST OF EFFECTIVE PAGES PAGE DATE 607 608 ASSEMBLY 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739 740 NOV 29/07 NOV 29/07 NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV NOV 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07 29/07
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LIST OF EFFECTIVE PAGES PAGE DATE
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DATE
FITS AND CLEARANCES 801 NOV 802 NOV 803 NOV 804 NOV
SPECIAL TOOLS, FIXTURES AND EQUIPMENT 901 NOV 29/07 902 NOV 29/07
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TABLE OF CONTENTS
PAGE DESCRIPTION AND OPERATION TESTING AND FAULT ISOLATION UNASSIGNED DISASSEMBLY CLEANING CHECK REPAIR ASSEMBLY FITS AND CLEARANCES SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1 101 201 301 401 501 601 701 801 901
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DESCRIPTION AND OPERATION
1.
GENERAL A. This manual provides overhaul and maintenance instructions for the galley system, basic PN 1099L. The galley system consists of seven galley units, one bar unit, one closet unit and one coat closet unit. Part Numbers And Capacities UNIT GALLEY UNIT G1 GALLEY UNIT G2 GALLEY UNIT G3 GALLEY UNIT G4 GALLEY UNIT G5 GALLEY UNIT G6 GALLEY UNIT G7 BAR UNIT G4A RH CLOSET UNIT RH COAT CLOSET UNIT C. PART NUMBER 1099L11A00000 1099L12A00000 1099L21A00000 1099L22A00000 1099L44A00000 1099L41A00000 1099L42A00000 1099L23A00000 1099L13A00000 1099L24A00000 784.3 568.9 266.0 487.0 540.0 1146.2 1268.4 305.0 47.0 30.0 CAPACITY KG KG KG KG KG KG KG KG KG KG 1729.1 1254.2 586.4 1073.6 1190.5 2526.6 2796.3 672.4 103.6 66.1 POUNDS POUNDS POUNDS POUNDS POUNDS POUNDS POUNDS POUNDS POUNDS POUNDS
B.
The galley units are primarily food and beverage distribution and storage facilities. The galley units contain space and containers for storage, provisions for waste disposal, ovens, refrigerators, hot cups, hot jugs, beverage makers, espresso makers, warming compartments, bun warmers, trash compactors and trolleys to prepare food and drinks served during flight. Electrical wiring and connectors are provided to furnish heating and controlling facilities to the electrically operated equipment and to provide lighting in the working area. Water is supplied to the galley units G1, G4, G5, G6 and G7 by the airplane potable water system. Quick disconnect couplings are provided for the hot jugs to permit rapid replacement. Galley units G1, G4 and G6 are equipped with a sink with liquid drainage provision. The drainage piping is connected to the airplane inflight drainage system.
D.
E.
F.
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G.
The galley units are bolted down to the airplane floor by means of special fittings and are sealed to prevent penetration of moisture. Tie rods are provided for upper attachment of the galley units. Galley units G2, G4, G6 and G7 are equipped with a cooling system. The cooled compartments for trolleys are provided with a cooled air system.
H.
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2.
DESCRIPTION A. Structure (1) The galley units consist of a casing and door assemblies which are made of a light weight construction. Some units can be divided for ease of transportation and installation into and within the airplane. The galley unit structures consist of sandwich panels made of nomex with fiberglass coverplates (10mm - 0.394" thick and/or 22mm - 0.866" thick) and extrusions being bonded and/or riveted to the panels. The galley unit structures are formed from panels and shelves which are attached with screws and threaded bushings, special loaded areas e.g. sandwich borders and attachment points are filled with aluminum or nylon fillers. The following parts are made of stainless steel or covered with stainless steel sheets: (a) Sink, waste chute, waste flap, drip pan and hot cup retainer.
(2)
(3)
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GALLEY UNIT G1 FIGURE 1
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B.
Galley Unit G1 (PN 1099L11A00000) (1) The galley unit G1 provides space for: (refer to fig. 1) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 20.0 10.0 41.5 48.9 13.4 5.0 100.0 119.0 60.0 5.0 ----------------------------------44.1 22.1 91.5 107.8 29.5 11.0 220.5 262.3 132.3 11.0 -----------------------------------
(a) Two compartments for two standard units (b) Compartment for standard unit (c) Two compartments for steam ovens (d) Compartment for refrigerator (e) Compartment for beverage maker with rail (f) Stowage compartment (g) Four compartments for one F/S cart or two H/S carts (h) Compartment for trash compactor (i) Compartment for H/S trolley (j) Stowage compartment for equipment (radio beacon) (k) Control panel (l) Work light (m) Electrical outlet (n) Timer for hot cup (o) Hot cup 1 LTR with retaining mechanism (p) Shut off valve (q) Water filter (r) Water spigot (s) Sink (t) Drain stop valve (u) Back flow check valve (v) Paper clip (w) Mirror (x) Work counter top (y) Sliding work table (z) Exhaust air (za) Fresh air outlet
101A/B, 102A/B 103 104, 105 106 107 108 109, 110, 112, 113 111 114 115 51 54 55 56 57 61 62 63 64 65 68 74 77 84 85 88 89
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C.
Galley Unit G2 (PN 1099L12A00000) (1) The galley unit G2 provides space for: (refer to fig. 2) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 10.0 20.0 30.0 34.0 4.9 40.0 10.0 100.0 ------22.0 44.1 66.1 75.0 10.8 88.2 22.0 220.5 -------
(a) Warming compartment (b) Two compartments for two standard units (c) Compartments for two standard units (d) Compartments for microwave oven (e) Compartment for serving trays (f) Compartment for two standard units (g) Compartment for ice drawer with drain (h) Four compartments for one F/S cart or two H/S carts (i) Control panel (j) Work counter top (k) Sliding work table
201 202A/B, 203A/B 204A/B 205 206 207A/B 208 209, 210, 211, 212 51 84 85
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D.
Galley Unit G3 (PN 1099L21A00000) (1) The galley unit G3 provides space for: (refer to fig. 3) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 20.0 18.0 10.0 60.0 44.1 39.7 22.0 132.3
(a) Two compartments for two standard units (b) Two compartments for ice drawers (c) Stowage compartment (d) Three compartments for H/S carts
301A/B, 302A/B 303, 304 305 306, 307, 308
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E.
Galley Unit G4 (PN 1099L22A00000) (1) The galley unit G4 provides space for: (refer to fig. 4) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 20.0 5.0 40.4 13.5 12.1 14.5 41.5 100.0 20.0 --------------10.0 44.1 11.0 89.1 29.8 26.7 32.0 91.5 220.5 44.1 --------------22.0
(a) Two compartments for two standard units (b) Warming compartment (c) Compartment for steam oven (d) Compartment for espresso maker (e) Compartment for hot jug (f) Compartment for beverage maker (g) Compartment for refrigerator (h) Three compartments for one F/S cart or two H/S carts (i) Compartment for waste container (k) Control panel (l) LED light (m) Shut off valve (n) Water spigot (o) Sink (p) Waste flap (q) Sliding work table (r) LCD screen 23
401A/B, 402A/B 403 404 405 406 407 408 409, 410, 411 412 51 54 61 63 64 81 85 96
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F.
Galley Unit G5 (PN 1099L44A00000) (1) The galley unit G5 provides space for: (refer to fig. 5) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 20.0 10.0 10.0 5.0 10.0 100.0 100.0 --------------44.1 22.0 22.0 11.0 22.0 220.5 220.5 ---------------
(a) Four compartments for two standard units (b) Two compartments for two standard units (c) Stowage compartment (d) Two stowages for three blue trays (e) Two compartments for ice drawers with drains (f) Two compartments for one F/S cart or two H/S carts (g) Two compartments for F/S carts (h) Drain stop valve (i) Back flow check valve (j) Paper clip (k) Mirror (l) Work counter top (m) Sliding work table (n-) Wine bottle opener
501A/B, 502A/B, 503A/B, 504A/B 505, 507 506 508, 509 510, 511 512, 515 513, 514 65 68 74 77 84 85 90
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G.
Galley Unit G6 (PN 1099L41A00000) (1) The galley unit G6 provides space for: (refer to fig. 6) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 10.0 48.9 26.0 13.4 12.1 100.0 100.0 100.0 24.0 13.5 3.0 ------0.6 ------------------------22.0 107.8 57.3 29.5 26.7 220.5 220.5 220.5 52.9 29.8 6.6 ------1.3 -------------------------
(a) Seven compartments for standard units (b) Three compartments for refrigerators (c) Compartment for oven racks (d) Three compartments for beverage makers with rails (e) Three compartments for hot jugs (f) Compartment for F/S waste cart (g) Four compartments for F/S carts (h) Three compartments for one F/S cart or two H/S carts (i) Compartment for two folding carts (j) Compartment for emergency equipment (k) Stowage compartment (l) Control panel (m) Work light (o) Timer for hot cup (p) Hot cup 1 LTR with retaining mechanism (q) Shut off valve (r) Water filter (s) Water faucet (t) Sink (u) Drain stop valve with back flow check valve (v) Paper clip (w) Paper cup holder (x) Work counter top (y) Sliding work table (z) Vent (za) Gasper outlet (zb) Gasper outlet
601, 602, 603, 604, 605, 606, 607 608, 609, 610 611 612, 613, 614 615, 616, 617 618 619, 620, 621, 625 622, 623, 624 626 627 628 51 54 56 57 61 62 63 64 65 74 75 84 85 88 89 90
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H.
Galley Unit G7 (PN 1099L42A00000) (1) The galley unit G7 provides space for: (refer to fig. 7) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 18.0 10.0 78.0 3.4 44.0 100.0 100.0 100.0 119.0 2.1 10.0 5.4 --------------39.7 22.0 172.0 7.5 97.0 220.5 220.5 220.5 262., 4.6 22.0 11.9 ---------------
(a) Three compartments for bun warmers (b) Four compartments for standard units (c) Compartment for three oven racks (d) Compartment for 10 blue serving trays (e) Six compartments for steam ovens (f) Compartment for F/S cart (duty free) (g) Three compartments for one F/A cart or two H/S carts (h) Three compartments for F/S carts (i) Compartment for trash compactor (j) Compartment for defibrillator (k) Coat room (l) Compartment for two PBE (m) Control panel (o) Shut off valve (p) Paper clip (location TBD) (q) Work counter top (r) Sliding work table (s) Vent (t) Gasper outlet
701, 702, 703 704, 705, 706, 707 708 709 710, 711, 712, 713, 714, 715 716 717, 718, 719 720, 721, 722 723 724 725 726 51 61 74 84 85 88 89
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GALLEY UNIT G4A FIGURE 8
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I.
Bar Unit G4A (PN 1099L23A00000) (1) The bar unit G4A provides space for: (refer to fig. 8) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 30.0 15.0 15.0 120.0 5.0 20.0 --66.1 33.1) 33.1) 264.6 11.0 44.1 ---
(a) Coat room (b) Two compartments for two H/S carts (c) Three stowage compartments (d) Compartment for waste container (e) 15 LCD screen
4A01 (on two coat rods: (on stowage floor: 4A02A/B, 4A03A/B 4A04, 4A05, 4A06 4A07 96
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RH CLOSET UNIT FIGURE 9
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J.
RH Closet Unit (PN 1099L13A00000) (1) The RH closet unit provides space for: (refer to fig. 9) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 5.0 30.0 12.0 11.0 66.1 26.5
(a) Stowage compartment (b) Coat room (c) Stowage compartment for wheel chair
1R01 1R02 1R03
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RH COAT CLOSET UNIT FIGURE 10
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K.
RH Coat Closet Unit (PN 1099L24A00000) (1) The RH coat closet unit provides space for: (refer to fig. 10) EQUIPMENT DESIGNATION NUMBER CAPACITY PER COMPT KG POUNDS 30.0 15.0 15.0 --66.1 33.1) 33.1) ---
(a) Coat room (b) 15 LCD screen
201 96
(on two coat rods: (on stowage floor:
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3.
OPERATION A. Doors and drawers can be opened when the latch handle is operated. After storage or removal of items, the doors and drawers are locked in the stowed position by pushing until latch bolt engages into strike. CAUTION: DO NOT USE SIDE-HINGED DOORS AS A BRACE OR HANDHOLD. DO NOT CLOSE DOORS BY KICKING.
NOTE: If items deposited within a storage compartment are too numerous or bulky to allow the door to close, do not attempt to close door with force. Remove as many items as necessary to allow clearance for door closure. Do not open doors beyond angle of aperture and door swing. NOTE: Do not attempt to place more weight in any compartment than is allowed, shown by the safety placard within the compartment. B. All stowage compartments, storing containers, carriers, trolleys or other equipment are equipped with revolving catches to secure the equipment in its compartments. Operation of Electrical Circuits (1) Control panels in the galley units contain toggle switches, circuit breakers, illuminated switches and indicator lights that control the application of AC power to the electrically operating components and the work lights. Indicators light up when electrical power is applied to the associated components. The control panels also contain circuit breakers for protection from electrical overload. These circuit breakers are the press-to-reset type (push-pull) and should not be used as a switch function.
C.
(2) (3)
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TESTING AND FAULT ISOLATION 1. GENERAL A. This section provides procedures based on test point/location method for testing and fault isolation of galley units. Visual Check (1) Check all cables and electrical units for proper fit. Remove dirt, dust or any residue if necessary.
B.
C.
Dielectric and insulation resistance test must be performed at the end of each overhaul. (1) Insulation resistance test must be performed after completion of dielectric test.
D.
Test Equipment NOTE: Equivalent substitutes may be used for listed items.
EQUIPMENT/PART NO. Ohmmeter Voltmeter AC Voltmeter DC Insulation resistance measuring device Type: METRAWID M Measuring device for dielectric test Type: UH27
DESCRIPTION 0 to 100 K Ohms 0 to 250 V AC, 400 Hz 0 to 40 V DC Megohm bridge or hand crank generator. Range: 0 to 500 megohms at 500 V DC 1000, 1250 and 1500 V AC, 50 - 60 Hz
MANUFACTURER COMMERCIALLY AVAILABLE COMMERCIALLY AVAILABLE COMMERCIALLY AVAILABLE METRAWATT GMBH POSTFACH 1333 90003 NUERNBERG GERMANY ELEKTROTECHNISCHES LABORATORIUM DIPL ING RICHARD KARL BAUMANN 70825 KORNTAL GERMANY
TEST EQUIPMENT FIGURE 101
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E.
Terminal Lugs
PIDGE RING TONGUE TERMINALS (NICKEL PLATED COPPER TEFLON INSULATION 260C) ================================================================================= SYMBOL STUD mm WIRE COLOR NSA93650 MFR PN MFR SELL PN SIZE SIZE 4 2.84 24 - 22 BROWN 1 TA2203 152644 AMP 20 GREY 1 TA2006 152659 AMP 263 215 18 - 16 ORANGE 1 TA1601 50834 AMP 263 879 6 3.50 24 22 20 18 - 16 14 12 - 10 24 22 20 18 - 16 14 12 - 10 8 24 22 20 18 - 16 14 12 - 10 8 18 - 16 14 12 - 10 8 BROWN GREY ORANGE WHITE BLACK BROWN GREY ORANGE WHITE BLACK RED BROWN GREY ORANGE WHITE BLACK RED ORANGE WHITE BLACK RED 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 4 1 1 1 4 TA2204 TA2005 TA1602 TA1402 TA1002 TA2205 TA2003 TA1603 TA1403 TA1003 TC0805 TA2206 TA2004 TA1604 TA1404 TA1004 TC0805 TA1605 TA1405 TA1005 TC0806 152645 152658 50835 50839-1 50845 152646 152656 50836 50840 50845-1 132330-1 152647 152657 50836-1 50840-1 50845-2 132330-1 153107 50841 50846 132331-1 AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP AMP 1000 354 263 216 263 878 532 646 532 647 1000 355 263 217 263 873 263 916 263 917 263 875 1000 356 263 218 263 874 263 918 263 919 263 875 1001 408 532 648 532 649 263 877
4.18
10
4.83
1/4
6.35
SOLDER CONNECTION CRIMP CONNECTION
LIST OF TERMINAL LUGS FIGURE 102
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2.
TEST SETUP FOR TESTING THE GALLEY EQUIPMENT A. Test galley units with all electrical equipment installed.
3.
FAULT ISOLATION NOTE: Refer to wiring diagrams fig. 127 thru 139.
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A.
Oven (Refer To Wiring Diagrams Fig. 127, 130 And 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The oven is protected by a 15 A, 3 phase circuit breaker installed on the galley unit control panel. The oven is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) Set circuit breaker to ON position. Set oven to ON position.
(3)
Test procedure
Indicator on oven is energized.

NO
AC power and AC ground are available on power supply connector of oven.
YES
Oven is working properly. NOTE: Check direction of blower rotation.

NO YES
NO
Check the appropriate circuit breaker for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
YES
Replace oven.
Oven circuit is correct.
TEST PROCEDURE, OVEN FIGURE 103
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B.
Refrigerator (Refer To Wiring Diagrams Fig. 127, 130 And 132) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The refrigerator is protected by a 5 A, 3 phase AC circuit breaker installed on the galley unit control panel. The refrigerator is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) Set circuit breaker to ON position. Set refrigerator to ON position.
(3)
Test procedure
Indicator on refrigerator is energized.

NO YES
AC power and AC ground are available on power supply connector of refrigerator.
Refrigerator is working properly.

YES NO
NO
Check the appropriate circuit breaker for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required. Replace refrigerator.
YES
Refrigerator circuit is correct.
TEST PROCEDURE, REFRIGERATOR FIGURE 104
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105 29/07
C.
Beverage Maker (Refer To Wiring Diagrams Fig. 127, 130 And 132) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The beverage maker is protected by a 10 A, 3 phase circuit breaker installed on the galley unit control panel. The beverage maker is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) (c) Check that water connection is correct and beverage maker is filled properly. Set circuit breaker to ON position. Set beverage maker to ON position.
(3)
Test procedure
Indicator on beverage maker is energized.

NO
YES
AC power and AC ground are available on power supply connector of beverage maker.
Beverage maker is working properly.

NO
YES
NO
YES
Replace beverage maker.
Beverage maker circuit is correct.
TEST PROCEDURE, BEVERAGE MAKER FIGURE 105
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PAGE NOV
106 29/07
D.
Air Chiller (Refer To Wiring Diagrams Fig. 128, 130, 132 And 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The air chiller is protected by a 15 A, 3 phase AC circuit breaker and a 2.5 A, 1 phase DC circuit breaker installed on the galley unit control panel. The air chiller, installed outside of the galley, is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) (c) Check two indicator bulbs on control panel (if necessary replace them). Set AC and DC power circuit breaker to ON position. Set switch to ON position.
(3)
Test procedure
Indicator ON on e-panel is illuminated.

NO
YES
AC, DC power and DC ground is available on power supply connector of air chiller.
Air chiller is working properly.

NO
YES
NO
Check the appropriate circuit breaker, XFMR rectifier and switch for proper switching and continuity of wiring per apropriate wiring diagram. Rework as required.
YES
When the fault indicator on e-panel is lighting.

NO
Check air chiller per chiller manual. Replace if required.

YES
ON indicator on e-panel is illuminated.

NO
YES
Replace bulb and/or indicator.
Air chiller circuit is correct.
TEST PROCEDURE, AIR CHILLER FIGURE 106
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PAGE NOV
107 29/07
E.
Microwave Oven (Refer To Wiring Diagram Fig. 128) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of a connector on top of the galley unit. The microwave oven is protected by a 10 A, 3 phase circuit breaker installed on the galley unit control panel. The microwave oven is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) Set circuit breaker to ON position. Set microwave oven to ON position.
(3)
Test procedure
Indicator on microwave oven is energized.

NO
AC power and AC ground are available on power supply connector of microwave oven.
YES
Microwave oven is working properly.

YES
NO
NO
Replace microwave oven.

YES
Microwave oven circuit is correct.
TEST PROCEDURE, MICROWAVE OVEN FIGURE 107
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108 29/07
F.
Espresso Maker (Refer To Wiring Diagram Fig. 130) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of a connector on top of the galley unit. The espresso maker is protected by a 10 A, 3 phase circuit breaker installed on the galley unit control panel. The espresso maker is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) (c) Check that water connection is correct and espresso maker is filled properly. Set circuit breaker to ON position. Set espresso maker to ON position.
(3)
Test procedure Indicator on espresso maker is energized.

NO YES
AC power and AC ground are available on power supply connector of espresso maker. Check the appropriate circuit breaker for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required. Replace espresso maker.
Espresso maker is working properly.

NO
NO YES
YES
Espresso maker circuit is correct.
TEST PROCEDURE, ESPRESSO MAKER FIGURE 108
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109 29/07
G.
Trash Compactor (Refer To Wiring Diagrams Fig. 127 And 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The trash compactor is protected by a 5 A, 3 phase circuit breaker installed on the galley unit control panel. The trash compactor is connected to the wiring of the galley unit by means of a pigtail with plug.
(2)
Test preparation (a) (b) Set circuit breaker to ON position. Set trash compactor to ON position.
(3)
Test procedure Indicator on trash compactor is energized.
NO
AC power and AC ground are available on power supply connector of trash compactor. Check the appropriate circuit breaker for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
YES
Trash compactor is working properly.

NO YES
NO
YES
Replace trash compactor.
Trash compactor circuit is correct.
TEST PROCEDURE, TRASH COMPACTOR FIGURE 109
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110 29/07
H.
Hot Cup (Refer To Wiring Diagrams Fig. 127 And 132) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The hot cup is protected by a 5 A, 1 phase circuit breaker installed on the galley unit control panel. The hot cup is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) (c) Fill the hot cup with water. Set circuit breaker to ON position. Set rotary timer switch to ON position.
(3)
Test procedure
Indicator on hot cup is energized.

NO
AC power and AC ground are available on power supply connector of hot cup.
YES
NO
Hot cup is working properly.

NO
YES
YES
Check the appropriate circuit breaker and rotary switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
Replace hot cup.
Hot cup circuit is correct.
TEST PROCEDURE, HOT CUP FIGURE 110
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PAGE NOV
111 29/07
I.
Work Light (Refer To Wiring Diagrams Fig. 127, 130 And 132) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The work light is protected by a 1 A, 1 phase circuit breaker installed on the galley unit control panel. A switch is installed on the control panel to set the work light to BRT or DIM or OFF position. The work light is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) Set circuit breaker to ON position. Set switch to BRT position.
(3)
Test procedure Work light is lighting bright.

NO YES
AC power and AC ground are available on power supply connector of work light. Check the appropriate circuit breaker and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
After setting switch to DIM position, work light is lighting dim.

NO YES
NO
YES
Replace work light.
Work light circuit is correct.
TEST PROCEDURE, WORK LIGHT FIGURE 111
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PAGE NOV
112 29/07
J.
Outlet (Refer To Wiring Diagram Fig. 127) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of a connector on top of the galley unit. The outlet is protected by a 10 A, 1 phase circuit breaker installed on the galley unit control panel. The outlet is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) Set circuit breaker to ON position. Set switch to ON position.
(3)
Test procedure
Indicator ON on panel is lighting.
NO YES
Power is available on power supply connector of outlet. Check the appropriate circuit breaker and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
Outlet is working properly.
NO YES
After replacing the bulbs of indicator, the indicator is lighting. Check appropriate wiring for continuity according to appropriate wiring diagram. Rework as required.
YES
NO
NO YES
Replace outlet.
Outlet circuit is correct.
TEST PROCEDURE, OUTLET FIGURE 112
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113 29/07
K.
Warming Compartment (Refer To Wiring Diagrams Fig. 127 And 130) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The warming compartment is protected by a 7.5 A, 1 phase AC circuit breaker installed in the galley unit control panel. The warming compartment is controlled by the galley unit control panel. The warming compartment is connected to the wiring of the galley unit by means of a terminal board.
(2)
(3)
Test procedure
Warming compartment is energized. AC power and AC ground are available on power supply terminal board of warming compartment.
NO YES
Warming compartment is working properly.
NO YES
Check the appropriate circuit breaker and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
NO YES
Replace warming compartment.
Appropriate indicator is illuminated.

NO YES
Warming compartment circuit is correct. TEST PROCEDURE, WARMING COMPARTMENT FIGURE 113
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114 29/07
L.
XFMR Rectifier (Refer To Wiring Diagrams Fig. 128, 130, 132 And 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The XFMR rectifier is protected by a 2.5 A, 1 phase circuit breaker installed on the galley unit control panel. The XFMR rectifier is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) Set circuit breaker to ON position.
(3)
Test procedure
Power lamp on XFMR rectifier is energized.
NO YES
AC power and AC ground are available on power supply connector of XFMR rectifier. Check the appropriate circuit breaker for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required. Replace XFMR rectifier.
XFMR rectifier is working properly.

NO YES
NO
YES

NO YES
XFMR rectifier circuit is correct.
TEST PROCEDURE, XFMR RECTIFIER FIGURE 114
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115 29/07
M.
Hot Jug (Refer To Wiring Diagrams Fig. 130 And 132) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The hot jug is protected by a 5 A, 1 phase circuit breaker installed on the galley unit control panel. The hot jug is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) (c) Fill the hot jug with water. Set circuit breaker to ON position. Set switch to ON position.
(3)
Test procedure
Hot jug is energized.
NO
YES
Power is available on power supply connector of hot jug.
Hot jug is working properly.

YES
NO
YES
NO
Check the appropriate circuit breaker and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
Replace hot jug.

NO
YES
Hot jug circuit is correct.
TEST PROCEDURE, HOT JUG FIGURE 115
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116 29/07
N.
Ceiling Light (Refer To Wiring Diagrams Fig. 130 And 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The ceiling light is protected by a 2.5 A, 1 phase circuit breaker for the AC circuit and a 2.5 A, 1 phase circuit breaker for the DC circuit installed on the galley unit control panel. A rotary switch is installed on the control panel to set the ceiling light to BRT or DIM2 or DIM1 or OFF position. The ceiling light is connected to the wiring of the galley unit by means of connectors.
(2)
Test preparation (a) (b) Set AC, DC circuit breakers to ON position. Set rotary switch to BRT position.
(3)
Test procedure
Ceiling light is lighting bright.
NO YES
After replacing the fluorescent tubes, ceiling light is lighting.

YES NO
After setting rotary switch to DIM2 position, ceiling light is lighting dim.
NO YES
AC,DC power and AC, DC ground are available on power supply connector of ballast unit.
YES NO
Replace ballast unit.
After setting rotary switch to DIM1 position, ceiling light is lighting dim.
NO YES
Check the appropriate circuit breakers, XFMR rectifier and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
Ceiling light circuit is correct.
TEST PROCEDURE, CEILING LIGHT FIGURE 116
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117 29/07
O.
Area Light (Refer To Wiring Diagrams Fig. 130 And 137) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The area light is protected by a 2.5 A, 1 phase circuit breaker for the AC circuit and a 2.5 A, 1 phase circuit breaker for the DC circuit installed on the galley unit control panel. A rotary switch is installed on the control panel to set the area light to BRT or DIM2 or DIM1 or OFF position. The area light is connected to the wiring of the galley unit by means of connectors.
(2)
Test preparation (a) (b) Set AC, DC circuit breakers to ON position. Set rotary switch to BRT position.
(3)
Test procedure
Area light is lighting bright.
NO YES
After replacing the fluorescent tubes, area light is lighting.

YES NO
After setting rotary switch to DIM2 position, area light is lighting dim.
NO YES
AC,DC power and AC, DC ground are available on power supply connector of ballast unit.
YES NO
Replace ballast unit.
After setting rotary switch to DIM1 position, area light is lighting dim.
NO YES
Check the appropriate circuit breakers, XFMR rectifier and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
Area light circuit is correct.
TEST PROCEDURE, AREA LIGHT FIGURE 117
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PAGE NOV
118 29/07
P.
Heat Tape (Refer To Wiring Diagrams Fig. 132 And 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The heat tape is protected by a 2.5 A, 1 phase circuit breaker and by 1.6 A fuse installed on the galley unit control panel. The heat tape is connected to the wiring of the galley unit by means of a terminal block.
(2)
Circuit function (a) (b) (c) Check indicator bulbs of illuminated indicators on control panel. Set circuit breakers to ON position. Check additional fuses (1.6 A FF) on the control panel. NOTE: 1 2 Use cooling spray for testing the thermostat (less than 4C). Check the performance of the heating system by pushing TEST button without cooling the thermostats.
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119 29/07
(3)
Test procedure
Heat tape power and cycle indicators are energized. AC power and AC ground are available on power supply terminal blocks of heat tape. Check the appropriate circuit breaker and thermostats for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required. When necessary replace thermostats.
NO
YES YES
NO
Replace heating elements.
Heat tape is working properly.

NO YES
Appropriate indicators are illuminated.

NO YES
Replace bulbs and/or indicator.
Heat tape circuit is correct.
TEST PROCEDURE, HEAT TAPE FIGURE 118
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PAGE NOV
120 29/07
Q.
Bun Warmer (Refer To Wiring Diagram Fig. 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of a connector on top of the galley unit. The bun warmer is protected by a 5 A, 1 phase circuit breaker installed on the galley unit control panel. The bun warmer is connected to the wiring of the galley unit by means of a pigtail with plug.
(2)
(3)
Test procedure
Indicator on bun warmer is energized.
NO YES
AC power and AC ground is available on power supply connector of bun warmer. Check the appropriate circuit breaker for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
Bun warmer is working properly.

YES NO
NO
Replace bun warmer.
YES
Bun warmer circuit is correct.
TEST PROCEDURE, BUN WARMER FIGURE 119
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PAGE NOV
121 29/07
R.
AIP And Handset (Refer to Wiring Diagrams Fig. 127, 132 And 133) (1) Circuit function (a) Power and data are supplied from the airplane to the galley by means of connectors on top of the galley units. The AIP and handset are directly controlled from the airplane. The AIP and handset are connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) Set control items in the airplane to ON position.
(3)
Test procedure
AIP and handset are working properly. Check the appropriate wiring per appropriate wiring diagram. Rework as required.
NO
YES
AIP and handset are working properly? Check AIP and handset per manufacturer's manual. Replace when necessary.
NO YES
AIP and handset circuit is correct.
TEST PROCEDURE, AIP AND HANDSET FIGURE 120
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PAGE NOV
122 29/07
S.
Attendant Work Light Switch (Refer To Wiring Diagrams Fig. 132, 133 And 137) (1) Circuit function (a) Power is supplied from the airplane to the partition by means of connectors on top of the pelmet G6/G7. The work light is controlled from the airplane and can be switched by this attendant work light switch. The work light is connected to the wiring of the pelmet by means of connectors.
(2)
Test preparation (a) (b) (c) Set control item in the airplane to ON position. Set switch to ON position. Ensure that ballast units and fluorescent tubes are working properly.
(3)
Test procedure Work light is lighting. Proper electrical signals according to system specification are available on contacts of appropriate receptacle. Check the appropriate control items in the airplane for proper switching. Rework as required. Check appropriate wiring of partition and pelmet per wiring diagram.
NO YES
NO YES
Switch is working properly (switching ON/OFF the lights).
NO YES
Replace switch.
Switch circuit is correct.
TEST PROCEDURE, ATTENDANT WORK LIGHT SWITCH FIGURE 121
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123 29/07
T.
AFT Area Heating (Refer To Wiring Diagram Fig. 133) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of a connector on top of the galley unit. The AFT area heating is controlled from the airplane. A switch is installed on the control panel to set the AFT area heating to LOW or HIGH or OFF position. The AFT area heating is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) (b) (c) Check indicator bulbs on control panel (if necessary replace them). Set control items in the airplane to ON position. Set switch to LOW position.
(3)
Test procedure
AFT area heating operated with low temperature.
NO YES
AC, DC power and AC, DC ground are available on power supply connector of area light. Check the appropriate control items and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
After setting switch to HIGH position, AFT area heating operated with high temperature.
NO YES
NO
YES
Replace switch or AFT area heating.
AFT area heating circuit is correct.
TEST PROCEDURE, AFT AREA HEATING FIGURE 122
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PAGE NOV
124 29/07
U.
LED Feature Light (Refer To Wiring Diagram Fig 134) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The LED feature light is protected by a 1 A, 1 phase circuit breaker installed on the galley unit control panel. The LED feature light is connected to the wiring of the galley unit by means of a connector.
(2)
(3)
Test procedure
LED feature light is lighting.
NO
YES
DC power and DC ground are available on power supply connector of LED feature light.
Check the appropriate circuit breaker, XFMR rectifier and switch for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
LED feature light is working properly.

NO
YES
NO
YES
Replace LED feature light.
LED feature light circuit is correct.
TEST PROCEDURE, LED FEATURE LIGHT FIGURE 123
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PAGE NOV
125 29/07
V.
Spot Light (Refer To Wiring Diagram Fig 135) (1) Circuit function (a) Power is supplied from the airplane to the galley by means of connectors on top of the galley units. The spot light is controlled from the airplane. A switch is installed behind the door to set the spot light to ON or OFF position. The spot light is connected to the wiring of the stowage by means of a connector.
(2)
Test preparation (a) (b) Set control items in the airplane to ON position. Open door.
(3)
Test procedure
Spot light is lighting.
NO
Power and ground are available on power supply connector of spot light.
Check the appropriate control items and switches for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required.
YES
Spot light is working properly.

NO
YES
NO
Replace spot light.

YES
Spot light circuit is correct.
TEST PROCEDURE, SPOT LIGHT FIGURE 124
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PAGE NOV
126 29/07
W.
Ballast Unit (Refer To Wiring Diagrams Fig. 138 And 139) (1) Circuit function (a) Power and control signals are supplied from the airplane to the galley by means of connectors on top of the galley units. The ballast unit is controlled from the airplane. The ballast unit is connected to the wiring of the galley unit by means of a connector.
(2)
Test preparation (a) Set control item in the airplane to ON position.
(3)
Test procedure Fluorescent lamp is lighting. After replacing the fluorescent tubes, lamp is lighting. Power and ground are available on contacts of connector. Check the appropriate control items in the airplane for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required. Replace ballast unit. Ballast unit circuit is correct.
NO
NO
YES YES NO
YES
TEST PROCEDURE, BALLAST UNIT FIGURE 125
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127 29/07
X.
Attendant Info Unit (Refer To Wiring Diagram Fig. 139) (1) Circuit function (a) Power is supplied from the airplane to the pelmet unit G6/G7 by means of a connector on top of the pelmet unit G6/G7. The info unit is controlled from the airplane. The info unit is connected to the wiring of the pelmet unit G6/G7 by means of a connector.
(2)
Test preparation (a) Set switch to ON position.
(3)
Test procedure Info unit is energized.

NO
Power and ground are available on power supply connector of info unit.
YES
Info unit is working properly.

NO
NO
Check the appropriate control items in the airplane for proper switching and continuity of wiring per appropriate wiring diagram. Rework as required. Replace info unit.
YES
YES
Info unit circuit is correct.
TEST PROCEDURE, ATTENDANT INFO UNIT FIGURE 126
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128 29/07
4.
DIELECTRIC AND INSULATION RESISTANCE TEST CAUTION: DIELECTRIC AND INSULATION TEST CRITERIA VARY FOR INDIVIDUAL COMPONENTS. TO AVOID COMPONENT DAMAGE, CAREFULLY FOLLOW TEST PROCEDURES AND PRESCRIBED VOLTAGE WHEN PERFORMING THESE TESTS ON GENERAL WIRING OR INDIVIDUAL COMPONENTS. DIELECTRIC AND INSULATION RESISTANCE TEST MUST BE PERFORMED AT THE END OF EACH OVERHAUL. INSULATION RESISTANCE TEST MUST BE PERFORMED AFTER COMPLETION OF DIELECTRIC TEST. A. General CAUTION: PAY ATTENTION TO GENERAL SAFETY RULES. (1) Dielectric test at 1000 V AC Dielectric test is performed with each wire in each wire bundle against all other wires in the bundle and against the control panel. Max. fault current allowed must not exceed 0.5 milliamperes. When the equipment consists of more than one circuit which must be tested, each application of the specified test voltage shall be for a period of one minute only. (2) Dielectric test at 1250 V AC Dielectric test is performed with each wire in each wire bundle against all other wires in the bundle and against the control panel. Max. fault current allowed must not exceed 0.5 milliamperes. When the equipment consists of more than one circuit which must be tested, each application of the specified test voltage shall be for a period of one minute only. (3) Insulation resistance test Insulation resistance measuring device used at 500 V DC is a hand crank generator or battery operated device. Insulation resistance is measured between each wire in each wire bundle against all other wires in the bundle and against the control panel. NOTE: The insulation resistance must be a minimum of 200 megohms for each wire. (4) Electrical bonding test (Static ground measurement) At maintenance- and modification work it must be taken care that the requirements of the airplane manufacturer will be fulfilled.
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B.
Test Preparation General (1) (2) (3) Set circuit breakers to ON position. Set switches to ON or BRT position. Disconnect ovens, refrigerators, beverage makers, air chillers, microwave ovens, espresso makers, trash compactors, hot cups, work lights, warming compartments, XFMR rectifiers, hot jugs, ceiling lights, area lights, heat tapes, bun warmers, handsets, AFT area heating, LED feature lights, spot lights, ballast units, floor temperature setting panel and attendant info unit from galley wiring. Replace relays and XFMR rectifiers by wire jumpers. Remove bulbs and fluorescent tubes from control lights and pelmet lights. Disconnect galley unit G4 from bar unit G4A and from pelmet unit G3/G4, galley unit G6 from AFT partition, galley unit G7 from pelmet unit G6/G7, AFT partition from galley unit G7 and from pelmet unit G6/G7.
(4) (5) (6)
C.
Measuring Procedures (1) Measuring procedure - Unit G1 (refer to wiring diagram fig 127) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 Terminal lugs at wire with numbers 11H001A8A, 11H002A8B, 11H003A8C, 11H004A8N; A, B, C, D, E and F of plug (303A) and ground stud (800). (2) Measuring procedure - Unit G2 (refer to wiring diagram fig 128) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 Terminal lugs at wire with numbers 12H001A8A, 12H002A8B, 12H003A8C, 12H004A8N and ground stud (800).
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(3)
Measuring procedure - Unit G4 (refer to wiring diagram fig 130) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 Terminal lugs at wire with numbers 22H001A8A, 22H002A8B, 22H003A8C, 22H004A8N; 22H101A8A, 22H102A8B, 22H103A8C, 22H104A8N; A, B, C, D, E, F, G, H, J, K, L, M and P of receptacle (500A) and ground stud (800).
(4)
Measuring procedure - Unit G6 (refer to wiring diagram fig 132) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 Terminal lugs at wire with numbers 41H001A8A, 41H002A8B, 41H003A8C, 41H004A8N; A, B, C, D, E and F of receptacle (510A); 41H201A8A, 41H202A8B, 41H203A8C, 41H204A8N; L, M, N, P, R, S, T, U and V of receptacle (250) and terminal lug (801).
(5)
Measuring procedure - Unit G7 (refer to wiring diagram fig 133) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 Terminal lugs at wire with numbers 42H001A10A, 42H002A10B, 42H003A10C, 42H004A10N; 42H101A10A, 42H102A10B, 42H103A10C, 42H104A10N; L, M, N, P, R, S, T, U and V of receptacle (350); 42H201A10A, 42H202A10B, 42H203A10C, 42H204A10N; D, E, G, H and K of receptacle (310) and ground stud (801).
(6)
Measuring procedure - Bar Unit G4A (refer to wiring diagram fig 134) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 A, B, C and D of plug (160A) and ground stud (800).
(7)
Measuring procedure - RH Closet (refer to wiring diagram fig 135) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 A and B of plug (10A) and ground stud (810).
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(8)
Measuring procedure - Unit AFT Partition (refer to wiring diagram fig 137) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 C and D of plug (150A); A, C, D, E, G and H of plug (650A) and ground stud (801).
(9)
Measuring procedure - Pelmet Unit G3/G4 (refer to wiring diagram fig 138) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 All contacts of plug (510A); all contacts of plug (530A) and ground studs (920, 940).
(10)
Measuring procedure - Pelmet Unit G6/G7 (refer to wiring diagram fig 139) (a) Perform pin to pin dielectric and insulation resistance test per para. 4.A.(1) and 4.A.(3) between the following contacts: 1 All contacts of receptacle (1) and terminal lug (800).
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APPLICABLE TO WIRING DIAGRAM FIG 127 SH 7 THRU 9 ITEM 1 2 THRU 3 BLANK 4 5 6 7 8 THRU 9 BLANK 10 11 12 13 14 15 THRU 19 BLANK 20 21 22 23 24 25 THRU 29 BLANK 30 31 32 33 34 THRU 39 BLANK 40 41 41A 42 43 BLANK 44 45 46 47 48 49 BLANK 50 51 BLANK continued NOMENCLATURE MOUNTING BRACKET CONDUIT CONTROL PANEL CONTROL MODULE COVER CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET CIRCUIT BREAKER RECEPTACLE PLUG CLAMP GROMMET NUT MOUNTING BRACKET GROUND STUD GROUND STUD GROUND STUD CIRCUIT BREAKER QTY 1 AR 1 1 1 1 1 3 1 2 1 1 3 1 2 1 1 3 3 1 1 1 1 1 1 1 1 1 1 PART NUMBER 0-211-010400000 NSA935805-20 1099L11A20200 1099L11A20330 1099L11A20340 BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130 BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130 BACC18AC5 ACR6-33 857-0590-130 857-0591-130B BACC18AC10 BACC45FN14-7SN BACC45FT14-7PN NSA938112-14C 610ES012C14 0-211-000603000 00-882 00-1433 5026-02-0008 BACC18Z5R
WIRING DIAGRAM - ELECTRICAL COMPONENTS -UNIT G1FIGURE 127 SH 1 OF 9
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ITEM continued 51A 52 53 54 55 56 57 58 59 BLANK 60 61 62 63 64 65 66 67 68 69 70 71 72 BLANK 72A 73 74 75 THRU 79 BLANK 80 81 82 83 84 85 THRU 300 BLANK 300A 301 302 303 BLANK continued
NOMENCLATURE
QTY
PART NUMBER
PLUG CLAMP DUMMY RECEPTACLE MOUNTING PLATE SOLDERING SLEEVE GROUND STUD BRACKET GROUND STUD CONDUIT CIRCUIT BREAKER INDICATOR LIGHT BULB RECEPTACLE TIMER KNOB FASTEN TAP TIMER BRACKET SPACER CASING CIRCUIT BREAKER TOGGLE SWITCH PLUG CLAMP WORK LIGHT CIRCUIT BREAKER TOGGLE SWITCH RECEPTACLE INDICATOR LIGHT BULB PLUG CLAMP CLAMP
1 1 1 1 2 1 1 AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1
MS24266R14B7SN MS27291-3 MS27297-3 0-211-001000003 D144-05 0-212-000201000 00-1433 NSA935805-14 BACC18Z5R 14-32280-8P6 0LN115-18K ACHC3-13 601LK8 6001-0324 DAN387-01 1096L21A20500 0-211-006000000 DAN387-02 BACC18Z1R MS27407-1 BACC45FT8-3SN NSA938112-08C01 LD0500-121 BACC18Z10R MS24523-23 5258SSI 14-32280-8P6 0LN115-18K 0237E15S03A NSA938421-01 NSA938422-02
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ITEM continued 303A 304 305 BLANK 306 307 THRU 599 600 601 602 603 THRU 699 700 701 702 THRU 703 704 705 BLANK 706 707 THRU 710 711 712 BLANK 713 714 THRU 719 720 721 BLANK 722 723 724 725 THRU 739 740 741 742 743 744 745 746 THRU 759 760 761 762 continued
NOMENCLATURE
QTY
PART NUMBER
PLUG CABLE BRACKET BLANK BRACKET TERMINAL BOARD COVER TERMINAL BUS WIRE WIRE WIRE WIRE WIRE WIRE DISTANCE SLEEVE CLAMP CLAMP WASHER SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE CONDUIT CONDUIT CONDUIT
1 1 1 1 1 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR
ABS0364B10PC ABS0364C 5001L11A203101 MS27212-2-4 MS18029-2S4 MS25226-4-4 EN2267-008A090P EN2267-008A051P EN2267-008A012P EN2267-008A006P ASNE0274UD20 ASNE0264PF22 00-1427 BACC10GE NSA935807 NSA935808-01 NSA937201MA0401 NSA937201MA0403 NSA937201MA0402 NSA937201MA0801 NSA937201MA0803 NSA937201MA0802 NSA935805-06 NSA935805-09 NSA935805-10
BLANK BLANK
BLANK
BLANK
BLANK
BLANK
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ITEM continued 763 764 BLANK 765 766 THRU 799 BLANK 800 801 THRU 809 BLANK 810 811 812 813 814 BLANK 815 816 817 818 819 BLANK 820 821 822 823 824 825 826 827 828 THRU 829 BLANK 830 831 832 833 BLANK 834 835 836 837 838 839 840 BLANK continued
NOMENCLATURE
QTY
PART NUMBER
CONDUIT CONDUIT GROUND STUD GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD STUD STUD STUD STUD STUD BRACKET STUD STUD STUD STUD STUD STUD STUD
AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NSA935805-14 NSA935805-20 5026-02-0016 0-212-000202000 00-1433 00-1433 00-1433 0-212-001000000 00-882 5026-02-0008 00-882 0-212-000202000 00-1433 00-1433 00-1433 00-1433 00-882 0-212-001000000 00-882 0-212-000102000 00-1433 00-1433 5026-02-0009 00-1433 00-1433 00-882 00-882 5026-02-0008
GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND GROUND GROUND STUD STUD STUD STUD STUD STUD
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ITEM continued 841 842 843 844 845 846 847 848 849 850 BLANK 851 852 853 THRU 859 860 861 862 863 864 BLANK 865 866 THRU 868 869 870 871 872 THRU 873 874 875 THRU 899 900
NOMENCLATURE
QTY
PART NUMBER
GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND
STUD STUD STUD STUD STUD STUD STUD STUD STUD
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
00-1433 00-1433 5026-02-0009 00-882 00-882 00-882 00-882 5026-02-0009 00-1516 00-882 00-882 0-212-001502000 00-882 00-882 00-882 00-882 00-882 00-882 00-1472 00-1472 5026-02-0016
BLANK
GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD
BLANK
GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD
BLANK BLANK
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REVISION REFERENCE SHEET Rev Code Revision Description Serial No. Effectivity
REVISION REFERENCE SHEET FIGURE 127 SH 6 OF 9
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WIRING DIAGRAM UNIT G1FIGURE 127 SH 7 OF 9
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APPLICABLE TO WIRING DIAGRAM FIG 128 SH 5 ITEM 1 THRU 3 BLANK 4 5 6 7 8 THRU 9 BLANK 10 11 BLANK 11A 12 13 14 15 16 17 18 19 BLANK 20 20A 21 22 23 24 THRU 29 BLANK 30 31 32 33 34 35 36 37 38 THRU 39 BLANK 40 41 41A 42 43 THRU 44 BLANK continued NOMENCLATURE QTY PART NUMBER
CONDUIT CONTROL PANEL CONTROL MODULE COVER CIRCUIT BREAKER PLUG CLAMP INDICATOR LIGHT BULB CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB CIRCUIT BREAKER PLUG CLAMP DUMMY RECEPTACLE MOUNTING PLATE CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB TERMINAL BOARD COVER TERMINAL LUG MOUNTING BRACKET CIRCUIT BREAKER TRANSFORMER PLUG CLAMP
AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1
NSA935805-20 1099L12A20200 1099L12A20330 1099L12A20340 BACC18AC15 0052R14B12SN ABS0638A14 14-32280-6P6 MS25237-387 BACC18Z2R MS24523-23 14-32280-8P6 MS25237-387 BACC18AC10 MS3476L16-8SN MS3417-16N MS3115-16A 0-211-001000004 BACC18Z7R MS24523-23 14-32280-8P6 0LN115-18K MS27212-1-3 MS18029-1S3 36151 1007G41A21332 BACC18Z2R TR0140-00 MS24266R14B7SN NSA938112-14C
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ITEM continued 45 46 47 THRU 199 200 201 202 THRU 599 600 601 602 603 THRU 699 700 701 702 THRU 703 704 705 BLANK 706 707 THRU 719 720 721 BLANK 722 723 724 725 THRU 739 740 741 742 743 THRU 759 760 761 762 763 764 BLANK 765 766 THRU 799 800 801 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK BLANK
INDICATOR LIGHT BULB WIRE BUNDLE BRACKET TERMINAL BOARD COVER TERMINAL BUS WIRE WIRE WIRE WIRE DISTANCE SLEEVE CLAMP CLAMP WASHER SLEEVE SLEEVE SLEEVE CONDUIT CONDUIT CONDUIT CONDUIT CONDUIT GROUND STUD GROUND STUD
1 1 1 1 1 1 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 1 1
14-32280-7P6 MS25237-387 RDAM7662-03 0-212-001300000 MS27212-2-3 MS18029-2S3 MS25226-4-2 EN2267-008A090P EN2267-008A051P EN2267-008A012P EN2267-008A006P 00-1427 BACC10GE NSA935807 NSA935808-01 NSA937201MA0401 NSA937201MA0403 NSA937201MA0402 NSA935805-06 NSA935805-09 NSA935805-10 NSA935805-14 NSA935805-20 5026-02-0016 5026-02-0016
BLANK BLANK
BLANK
BLANK
BLANK
BLANK
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ITEM continued 802 THRU 809 810 811 812 813 THRU 814 815 816 817 818 THRU 819 820 821 822 823 BLANK 824 825 THRU 829 830 831 832 833 834 835 836 837 838 839 THRU 841 842 843 844 THRU 849 850
NOMENCLATURE
QTY
PART NUMBER
BLANK
BLANK
GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD STUD STUD STUD STUD STUD
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0-212-000102000 00-1433 00-1433 00-882 00-1472 00-1472 0-212-000202000 00-1433 00-1433 00-1433 0-212-000202000 00-1433 00-1433 00-1433 0-212-001000000 00-882 00-1433 0-212-001000000 00-882 5026-02-0008 5026-02-0009 5026-02-0016
BLANK
BLANK
BLANK BLANK
GROUND STUD GROUND STUD GROUND STUD
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APPLICABLE TO WIRING DIAGRAM FIG 129 SH 3 ITEM 1 700 701 702 705 706 707 730 731 732 740 741 742 750 751 760 761 762 763 764 800 801 802 810 811 812 813 814 816 817 890 THRU 699 BLANK THRU 704 BLANK THRU 729 BLANK THRU 739 BLANK THRU 749 BLANK THRU 759 BLANK NOMENCLATURE QTY PART NUMBER
WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP WASHER CONDUIT CONDUIT CONDUIT GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD
AR AR AR AR AR AR AR AR AR AR AR AR 1 1 1 1 1 1 1 1
EN2267-008A090P EN2267-008A051P EN2267-008A010P EN2267-008A006P 00-1427 1032 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 NSA935805-10 5026-02-0016 5026-02-0016 0-212-000302000 00-1433 00-1433 00-1433 5026-02-0009 5026-02-0016
THRU 799 BLANK THRU 809 BLANK
GROUND STUD GROUND STUD
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WIRING DIAGRAM -UNIT G3FIGURE 129 SH 3 OF 3
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APPLICABLE TO WIRING DIAGRAM FIG 130 SH 8 THRU 11 ITEM 1 BLANK 2 3 4 BLANK 5 6 7 8 BLANK 9 10 11 11A 12 13 BLANK 14 15 16 17 18 THRU 19 BLANK 20 21 21A 22 23 24 25 26 27 28 THRU 29 BLANK 30 31 32 33 34 THRU 39 BLANK 40 41 42 continued NOMENCLATURE QTY PART NUMBER
CONDUIT CONDUIT CONTROL PANEL CONTROL MODULE COVER CONDUIT CIRCUIT BREAKER RECEPTACLE PLUG CLAMP GROMMET NUT MOUNTING BRACKET GROUND STUD GROUND STUD CIRCUIT BREAKER RECEPTACLE PLUG GROMMET NUT CLAMP GROUND STUD GROUND STUD MOUNTING BRACKET GROUND STUD CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET CIRCUIT BREAKER RECEPTACLE SOCKET
AR AR 1 1 1 AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 1 1 3
NSA935805-20 NSA935805-20 1099L22A20200 1099L22A20330 1099L22A20340 NSA935805-10 BACC18AC10 BACC45FN14-7SN BACC45FT14-7PN NSA938112-14C 610ES012C14 0-211-000603000 00-882 00-1433 BACC18AC10 BACC45FN14-7SN BACC45FT14-7PN 610ES012C14 NSA938112-14C01 00-882 00-1433 0-211-000608000 5026-02-0008 BACC18AC5 ACR6-33 857-0590-130 857-0591-130B BACC18AC15 ACR6-33 857-0590-130
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ITEM continued 43 44 THRU 49 BLANK 50 51 52 53 54 55 56 57 58 59 BLANK 60 61 62 63 64 65 66 67 THRU 69 BLANK 70 71 72 BLANK 72A 73 74 75 THRU 109 BLANK 110 111 111A 112 113 114 115 116 117 continued
NOMENCLATURE
QTY
PART NUMBER
SOCKET CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB TERMINAL BOARD COVER TERMINAL LUG MOUNTING BRACKET GROUND STUD CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB RECEPTACLE PLUG SUPPORT GROUND STUD CIRCUIT BREAKER TOGGLE SWITCH PLUG CLAMP WORK LIGHT CIRCUIT BREAKER CLAMP PLUG INDICATOR LIGHT BULB CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB
3 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
857-0591-130B BACC18Z7R MS24523-23 14-32280-8P6 0LN115-18K MS27212-1-3 MS18029-1S3 36151 1007G41A21332 00-1433 BACC18Z5R MS24523-23 14-32280-8P6 0LN115-18K CA16707 5034-02-0003 00-1461 BACC18Z1R MS27407-1 BACC45FT8-3SN NSA938112-08C01 LD0500-101 BACC18AC15 ABS0638A14 0052R14B12SN 14-32280-6P6 MS25237-387 BACC18Z2R MS24523-23 14-32280-8P6 MS25237-387
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ITEM continued 118 119 120 121 121A 122 123 THRU 159 160 161 162 THRU 164 165 166 167 THRU 179 180 181 182 183 184 185 THRU 199 200 201 202 THRU 500 500A 501 502 503 504 505 506 507 508 509 BLANK 510 511 512 513 THRU 514 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK BLANK BLANK
INDICATOR LIGHT BULB CIRCUIT BREAKER TRANSFORMER PLUG CLAMP RECEPTACLE CABLE BRACKET CIRCUIT BREAKER TOGGLE SWITCH CIRCUIT BREAKER COVER KNOB ROTARY SWITCH CIRCUIT BREAKER WIRE BUNDLE BRACKET PLUG CABLE BRACKET TERMINAL BLOCK TERMINAL BLOCK TERMINAL BLOCK TERMINAL BLOCK RAIL END CLAMP CONDUIT RECEPTACLE CABLE BRACKET CONSOLE
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 AR 1 1 1
14-32280-7P6 MS25237-387 BACC18Z2R TR0140-00 MS24266R14B7SN NSA938112-14C ABS0364A10SC ABS0364C BACC18Z1R MS24523-23 BACC18Z2R A4123100 A2623630 68-2148 BACC18Z2R RDAM7662-03 0-212-001300000 ABS0364B10PC ABS0364C NSA937901M2002 NSA937901M2002 NSA937901M2008 NSA937901M2008 NSA937901R080 NSA937901S NSA935805-06 ABS0364A26SC ABS0364C 5001L11A203101
BLANK BLANK
BLANK
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ITEM continued 515 516 517 518 THRU 529 530 531 532 533 THRU 534 535 536 537 538 THRU 599 600 601 602 603 THRU 609 610 611 612 613 THRU 699 700 701 702 THRU 703 704 705 706 707 708 THRU 712 713 714 THRU 729 730 731 732 THRU 739 740 741 742 THRU 749 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK
GROUND STUD BRACKET GROUND STUD GROUND STUD RECEPTACLE CABLE BRACKET CONSOLE GROUND STUD BRACKET GROUND STUD GROUND STUD TERMINAL BOARD COVER TERMINAL BUS TERMINAL BOARD COVER TERMINAL BUS WIRE WIRE WIRE WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AR AR AR AR AR AR AR AR AR AR AR
0-212-001502000 00-882 00-882 ABS0364A26SC ABS0364C 5001L11A203101 0-212-001502000 00-882 00-882 MS27212-2-3 MS18029-2S3 MS25226-4-3 MS27212-2-3 MS18029-2S3 MS25226-4-2 EN2267-008A090P EN2267-008A051P EN2267-008A012P EN2267-008A010P EN2267-008A006P EN2267-008A004P ASNE0264PF22 00-1427 1032 BACC10GE NSA935807
BLANK
BLANK
BLANK
BLANK BLANK
BLANK BLANK BLANK BLANK
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ITEM continued 750 751 THRU 759 760 761 762 763 764 BLANK 765 766 767 THRU 789 790 791 792 793 794 795 796 THRU 799 800 801 802 THRU 809 810 811 812 813 814 815 816 THRU 819 820 821 822 823 BLANK 824 825 826 827 BLANK 828 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK
WASHER CONDUIT CONDUIT CONDUIT CONDUIT CONDUIT CONDUIT SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD STUD STUD
AR AR AR AR AR AR AR AR AR AR AR AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NSA935808-01 NSA935805-06 NSA935805-09 NSA935805-10 NSA935805-14 NSA935805-20 NSA935805-32 NSA937201MA0401 NSA937201MA0403 NSA937201MA0402 NSA937201MA0801 NSA937201MA0803 NSA937201MA0802 5026-02-0016 5026-02-0016 0-212-000302000 00-882 00-882 0-212-001000000 0-212-000900000 00-882 0-212-001502000 00-882 00-882 00-1433 5026-02-0009 00-882 5026-02-0009
BLANK
BLANK BLANK
BLANK
GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD
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ITEM continued 829 BLANK 830 831 832 833 THRU 840 841 842 BLANK 843 844 845 846 847 THRU 849 850 851 852 853 THRU 869 870 871 872 873 THRU 879 880 881 882 883 THRU 889 890 891 892 THRU 899 900 901 902
NOMENCLATURE
QTY
PART NUMBER
BLANK
GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND STUD STUD STUD STUD
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
00-882 5026-02-0009 00-882 00-1433 5026-02-0009 00-882 00-882 5026-02-0009 0-212-000302000 00-882 00-882 0-212-000102000 00-1433 00-1433 00-882 00-1472 00-1472 5026-02-0016 5026-02-0016 1017L29A20300 00-882 00-882
BLANK
BLANK
GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD BRACKET GROUND STUD GROUND STUD
BLANK
BLANK BLANK
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APPLICABLE TO WIRING DIAGRAM FIG 131 SH 3 ITEM 1 700 701 702 730 731 732 740 741 742 750 751 760 761 762 787 788 789 790 800 801 810 811 812 813 814 815 816 817 819 820 821 822 823 824 825 826 890 THRU 699 BLANK THRU 729 BLANK THRU 739 BLANK THRU 749 BLANK THRU 759 BLANK THRU 786 BLANK NOMENCLATURE QTY PART NUMBER
WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP WASHER CONDUIT CONDUIT COVER COVER COVER GROUND STUD GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD
AR AR AR AR AR AR AR AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
EN2267-008A090P EN2267-008A051P 00-1427 1032 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 0-211-006300001 0-211-006300002 0-211-006300003 5026-02-0016 0-212-000202000 00-1433 00-1433 00-1433 5026-02-0008 0-212-001600000 00-1433 0-212-001000000 00-882 0-212-001600000 5026-02-0008 0-212-001000000 00-882 5026-02-0016
BLANK THRU 818 BLANK
GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND GROUND GROUND GROUND STUD STUD STUD STUD STUD STUD STUD
THRU 889 BLANK
GROUND STUD
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APPLICABLE TO WIRING DIAGRAM FIG 132 SH 11 THRU 16 ITEM 1 2 BLANK 3 4 5 6 7 8 THRU 9 BLANK 10 11 12 13 14 THRU 15 BLANK 16 17 THRU 19 BLANK 20 21 22 23 24 THRU 29 BLANK 30 31 32 33 34 THRU 35 BLANK 36 37 THRU 39 BLANK 40 41 41A 42 43 BLANK 44 45 46 47 48 continued NOMENCLATURE MOUNTING BRACKET CONDUIT CONDUIT CONTROL PANEL CONTROL MODULE COVER CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET GROUND STUD CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET GROUND STUD CIRCUIT BREAKER RECEPTACLE PLUG CLAMP GROMMET NUT MOUNTING BRACKET GROUND STUD GROUND STUD GROUND STUD QTY 1 AR AR 1 1 1 1 1 3 3 1 1 1 3 3 1 1 3 3 1 1 1 1 1 1 1 1 1 1 PART NUMBER 0-211-010900000 NSA935805-20 NSA935805-20 1099L41A20200 1099L41A20330 1099L41A20340 BACC18AC5 ACR6-33 857-0590-130 857-0591-130B 00-882 BACC18AC5 ACR6-33 857-0590-130 857-0591-130B BACC18AC5 ACR6-33 857-0590-130 857-0591-130B 00-882 BACC18AC10 BACC45FN14-7SN BACC45FT14-7PN NSA938112-14C 610ES012C14 0-211-000603000 00-882 00-1433 5026-02-0008
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ITEM continued 49 BLANK 50 51 51A 52 53 BLANK 54 55 56 57 58 59 BLANK 60 61 61A 62 63 BLANK 64 65 66 67 68 THRU 69 BLANK 70 71 72 73 74 75 76 THRU 79 BLANK 80 81 82 83 84 85 86 THRU 89 BLANK continued
NOMENCLATURE
QTY
PART NUMBER
CIRCUIT BREAKER RECEPTACLE PLUG CLAMP GROMMET NUT MOUNTING BRACKET GROUND STUD GROUND STUD GROUND STUD CIRCUIT BREAKER RECEPTACLE PLUG CLAMP GROMMET NUT MOUNTING BRACKET GROUND STUD GROUND STUD CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB RECEPTACLE BRACKET PLUG CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB RECEPTACLE BRACKET PLUG
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
BACC18AC10 BACC45FN14-7SN BACC45FT14-7PN NSA938112-14C 610ES012C14 0-211-000603000 00-882 00-1433 5026-02-0008 BACC18AC10 BACC45FN14-7SN BACC45FT14-7PN NSA938112-14C 610ES012C14 0-211-000608000 00-882 00-1433 BACC18Z5R MS24523-23 14-32280-8P6 0LN115-18K CA16707 5034-02-0003 BACC18Z5R MS24523-23 14-32280-8P6 0LN115-18K CA16707 5034-02-0003
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ITEM continued 90 91 92 93 94 95 96 THRU 99 BLANK 100 101 102 103 104 THRU 109 BLANK 110 111 112 113 114 115 116 117 118 119 THRU 120 BLANK 121 122 123 124 125 126 127 128 THRU 129 BLANK 130 131 132 133 134 135 continued
NOMENCLATURE
QTY
PART NUMBER
CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB RECEPTACLE PLUG SUPPORT CIRCUIT BREAKER INDICATOR LIGHT BULB RECEPTACLE CIRCUIT BREAKER FUSE HOLDER MINIATURE FUSE INDICATOR LIGHT BULB INDICATOR LIGHT BULB RESISTOR THRU BOLTS TERMINAL BLOCK RAIL END CLAMP THERMOSTAT HEAT TAPE GROUND STUD MOUNTING BRACKET CIRCUIT BREAKER FUSE HOLDER MINIATURE FUSE INDICATOR LIGHT BULB INDICATOR LIGHT
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1
BACC18Z5R MS24523-23 14-32280-8P6 0LN115-18K CA16707 5034-02-0003 BACC18Z5R 14-32280-8P6 0LN115-18K ACHC3-13 BACC18Z2R FHN26G1 70-125-40-1-6 14-32280-8P6 0LN115-18K 14-32280-8P6 MS25237-387 D25K300 7PA25 NSA937901M1605 NSA937901R0080 NSA937901S 11041-57-38 MSB115VAC15WATT 00-822 1023L41A20310 BACC18Z2R FHN26G1 70-125-40-1-6 14-32280-8P6 0LN115-18K 14-32280-8P6
25-05-04
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177 29/07
ITEM continued 136 137 138 139 140 140A 141 142 BLANK 143 144 145 146 147 BLANK 148 149 150 151 THRU 159 160 161 162 BLANK 162A 163 164 165 THRU 189 190 191 192 193 194 195 196 THRU 209 210 211 211A 212 THRU 219 220 continued
NOMENCLATURE
QTY
PART NUMBER
BULB RESISTOR THRU BOLTS TOGGLE SWITCH RECEPTACLE PLUG CABLE BRACKET CABLE BRACKET GROUND STUD MOUNTING BRACKET TERMINAL BLOCK HEAT TAPE THERMOSTAT MOUNTING BRACKET CIRCUIT BREAKER TOGGLE SWITCH PLUG CLAMP WORK LIGHT TIMER KNOB FASTEN TAP TIMER BRACKET DISTANCE SLEEVE CASING CIRCUIT BREAKER CLAMP PLUG CIRCUIT BREAKER
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 AR 1 1 1 1 1
MS25237-387 D25K300 7PA25 MS24524-30 ABS0364A10SC ABS0364B10PC ABS0364C ABS0364C 00-882 1027L41A20350 NSA937901M1605 MSB115V30WATT 11041-57-38 1020L41A20321 BACC18Z1R MS27407-1 BACC45FT8-3SN NSA938112-08C01 LD0500-121 601LK8 NZ6001-0324 DAN387-01 1096L42A20500 00-1427-5 DAN387-02 BACC18AC15 ABS0638A14 0052R14B12SN BACC18Z2R
BLANK
BLANK
BLANK
BLANK
25-05-04
PAGE NOV
178 29/07
ITEM continued 221 222 BLANK 222A 223 224 THRU 229 230 231 232 233 234 235 236 237 238 THRU 249 250 251 252 253 254 255 256 257 258 259 BLANK 260 260A 261 262 263 THRU 264 265 266 THRU 499 500 501 502 503 BLANK 504 continued
NOMENCLATURE
QTY
PART NUMBER
TRANSFORMER PLUG CLAMP CIRCUIT BREAKER INDICATOR LIGHT BULB TOGGLE SWITCH INDICATOR LIGHT BULB INDICATOR LIGHT BULB RECEPTACLE BACKSHELL PLUG SPRING LATCH FASTEN TAP HOUSING WIRE WIRE MOUNTING BRACKET RECEPTACLE PLUG CABLE BRACKET CONSOLE CABLE BRACKET RECEPTACLE CABLE BRACKET CONSOLE SOLDERING SLEEVE
1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 AR AR 1 1 1 1 1 1 1 1 1 1
TR0140-00 MS24266R14B7SN NSA938112-14C BACC18Z2R 14-32280-6P6 MS25237-387 MS24523-23 14-32280-8P6 MS25237-387 14-32280-7P6 MS25237-387 0053R14B19PNF ABSO638B14 0237E09S03A ABS0656A1B1 170-324-2 ABS0374B ASNE0272TK22 ASNE0264PF22 0-211-000603000 ABS0364A10SC ABS0364B10PC ABS0364C 5001L11A203101 ABS0364C ABS0364A10S ABS0364C 5001L11A203101 D101-31
BLANK
BLANK
BLANK BLANK
25-05-04
PAGE NOV
179 29/07
ITEM continued 505 506 THRU 510 510A 511 512 513 BLANK 514 515 516 THRU 599 600 601 602 603 THRU 609 610 611 612 613 THRU 699 700 701 702 THRU 703 704 705 BLANK 706 707 THRU 729 730 731 732 733 THRU 739 740 741 742 THRU 749 750 751 THRU 759 760 761 762 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK
WIRE PLUG CLAMP PIN SOLDERING SLEEVE CONDUIT TERMINAL BOARD COVER TERMINAL BUS TERMINAL BOARD COVER TERMINAL BUS WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE SPACER CLAMP CLAMP WASHER CONDUIT CONDUIT CONDUIT
AR 1 1 6 1 AR 1 1 1 1 1 1 AR AR AR AR AR AR AR AR AR AR AR AR AR
ASNE0272TK22 0052R12B10PNF ABS0638A12 NSA938151PA2000 D101-31 NSA935805-09 MS27212-2-5 MS18029-2S5 MS25226-4-5 MS27212-2-3 MS18029-2S3 MS25226-4-2 EN2267-008A090P EN2267-008A051P EN2267-008A012P EN2267-008A006P 00-1427 1032 1036L00A21320 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 NSA935805-10
BLANK
BLANK
BLANK BLANK
BLANK
BLANK BLANK BLANK
25-05-04
PAGE NOV
180 29/07
ITEM continued 763 764 765 766 767 768 THRU 789 790 791 792 793 794 795 796 THRU 799 800 801 802 THRU 809 810 811 812 813 814 BLANK 815 816 817 818 THRU 819 820 821 822 823 824 825 826 BLANK 827 828 THRU 829 830 831 continued
NOMENCLATURE
QTY
PART NUMBER
CONDUIT CONDUIT CONDUIT CONDUIT BLANK SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE GROUND STUD TERMINAL LUG GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD
AR AR AR AR AR AR AR AR AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
NSA935805-14 NSA935805-16 NSA935805-20 NSA935805-32 NSA937201MA0401 NSA937201MA0403 NSA937201MA0402 NSA937201MA0801 NSA937201MA0803 NSA937201MA0802 5026-02-0016 50845-2 0-212-000203000 00-1433 00-1433 00-1433 0-212-001000000 00-882 00-882 0-212-000202000 00-1433 00-1433 00-1433 0-212-001000000 00-882 00-882 0-212-001503000 00-882
BLANK BLANK
BLANK
GROUND STUD GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD STUD STUD
BLANK
GROUND STUD GROUND STUD BRACKET GROUND STUD
25-05-04
PAGE NOV
181 29/07
ITEM continued 832 833 834 835 836 837 838 839 840 841 842 843 844 845 846 847 848 THRU 859 860 861 862 863 864 THRU 865 866 867 868 869 870 871 872 873 THRU 879 880 881 882 883 THRU 889 890 891 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK
GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND
STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD BRACKET STUD STUD STUD STUD STUD STUD STUD STUD BRACKET STUD STUD
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
00-882 00-882 5026-02-0009 0-212-001000000 00-882 00-1433 00-882 00-1433 00-882 00-1472 5026-02-0009 00-882 5026-02-0008 00-882 5026-02-0008 5026-02-0008 0-212-000202000 00-1433 00-1433 00-1433 00-1461 00-1461 00-1461 00-1433 0-212-000102000 00-1433 00-1433 00-882 00-1472 00-1472 5026-02-0016 5026-02-0016
BLANK
BLANK
BLANK
GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD
25-05-04
PAGE NOV
182 29/07
ITEM continued 892 THRU 894 BLANK 895
NOMENCLATURE
QTY
PART NUMBER
TERMINAL LUG
50845-2
25-05-04
PAGE NOV
183 29/07
25-05-04
PAGE NOV
184 29/07
25-05-04
PAGE NOV
185/186 29/07
25-05-04
PAGE NOV
187/188 29/07
25-05-04
PAGE NOV
189/190 29/07
25-05-04
PAGE NOV
191/192 29/07
25-05-04
PAGE NOV
193/194 29/07
25-05-04
PAGE NOV
195/196 29/07
APPLICABLE TO WIRING DIAGRAM FIG 133 SH 10 THRU 14 ITEM 1 2 THRU 3 BLANK 4 5 6 7 8 THRU 9 BLANK 10 11 12 13 14 15 THRU 19 BLANK 20 21 BLANK 21A 22 23 24 25 26 27 28 THRU 29 BLANK 30 31 BLANK 31A 32 33 34 35 BLANK 36 37 THRU 39 BLANK 40 41 BLANK 41A 42 43 continued NOMENCLATURE MOUNTING BRACKET CONDUIT CONTROL PANEL CONTROL MODULE COVER CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET CIRCUIT BREAKER PLUG DUMMY RECEPTACLE CLAMP MOUNTING PLATE GROUND STUD BRACKET GROUND STUD GROUND STUD CIRCUIT BREAKER PLUG DUMMY RECEPTACLE CLAMP MOUNTING PLATE GROUND STUD CIRCUIT BREAKER PLUG DUMMY RECEPTACLE CLAMP QTY 1 AR 1 1 1 1 1 3 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PART NUMBER 0-211-011200000 NSA935805-32 1099L42A20200 1099L42A20330 1099L42A20340 BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130 BACC18Z5R BACC45FT14-7SN MS27297-3 NSA938112-14C 0-211-001000003 0-212-000102000 00-1433 00-1434 BACC18Z5R BACC45FT14-7SN MS27297-3 NSA938112-14C 0-211-001000003 00-1433 BACC18Z5R BACC45FT14-7SN MS27297-3 NSA938112-14C
25-05-04
PAGE NOV
197 29/07
ITEM continued 44 45 THRU 109 110 111 112 113 114 115 THRU 119 120 121 122 123 124 125 THRU 129 130 131 132 133 134 135 THRU 139 140 141 BLANK 141A 142 143 144 145 BLANK 146 147 148 THRU 209 210 211 212 213 214 215 THRU 219 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK
MOUNTING PLATE CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET CIRCUIT BREAKER PLUG CLAMP DUMMY RECEPTACLE MOUNTING PLATE SOLDERING SLEEVE CONDUIT CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET
1 1 1 3 1 2 1 1 3 1 2 1 1 3 1 2 1 1 1 1 1 2 AR 1 1 3 1 2
0-211-001000003 BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130 BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130 BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130 BACC18Z5R MS24266R14B7SN MS27291-3 MS27297-3 0-211-001000003 D144-05 NSA935805-14 BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130
BLANK
BLANK
BLANK
BLANK
BLANK
25-05-04
PAGE NOV
198 29/07
ITEM continued 220 221 222 223 224 225 THRU 229 BLANK 230 231 BLANK 231A 232 233 234 235 236 237 238 239 BLANK 240 241 241A 242 243 244 245 THRU 249 BLANK 250 251 252 253 254 255 256 257 258 259 THRU 278 BLANK 279 280 continued
NOMENCLATURE
QTY
PART NUMBER
CIRCUIT BREAKER RECEPTACLE SOCKET SOCKET SOCKET CIRCUIT BREAKER PLUG CLAMP INDICATOR LIGHT BULB CIRCUIT BREAKER TOGGLE SWITCH INDICATOR LIGHT BULB CIRCUIT BREAKER TRANSFORMER PLUG CLAMP INDICATOR LIGHT BULB CIRCUIT BREAKER FUSE HOLDER MINIATURE FUSE INDICATOR LIGHT BULB INDICATOR LIGHT BULB RESISTOR THRU BOLTS TOGGLE SWITCH RECEPTACLE
1 1 3 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
BACC18AC15 ACR6-33 857-0590-130 857-0591-130B 857-0591-130 BACC18AC15 0052R14B12SN ABS0638A14 14-32280-6P6 MS25237-387 BACC18Z2R MS24523-23 14-32280-8P6 MS25237-387 BACC18Z2R TR0140-00 MS24266R14B7SN MS27291-3 14-32280-7P6 MS25237-387 BACC18Z2R FHN26G1 70-125-40-1-6 14-32280-8P6 0LN115-18K 14-32280-8P6 MS25237-387 D25K300 7PA25 MS24524-30 ABS0364A10SC
25-05-04
PAGE NOV
198.1 29/07
ITEM continued 280A 281 282 BLANK 283 284 THRU 289 290 291 292 293 BLANK 294 295 296 297 298 THRU 300 301 302 THRU 309 310 311 312 313 314 315 316 317 318 319 320 321 THRU 339 340 341 342 343 344 345 THRU 349 350 351 continued
NOMENCLATURE
QTY
PART NUMBER
PLUG CABLE BRACKET BLANK CABLE BRACKET TERMINAL BLOCK RAIL END CLAMP THERMOSTAT HEAT TAPE GROUND STUD MOUNTING BRACKET MOUNTING BRACKET RECEPTACLE CLAMP PIN MOUNTING BRACKET INDICATOR LIGHT BULB INDICATOR LIGHT BULB INDICATOR LIGHT BULB TOGGLE SWITCH CIRCUIT BREAKER CIRCUIT BREAKER COVER KNOB ROTARY SWITCH RECEPTACLE BACKSHELL
1 1 1 1 1 2 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
ABS0364B10PC ABS0364C ABS0364C NSA937901M1605 NSA937901R0080 NSA937901S 11041-57-38 MSB115VAC15WATT 00-822 1023L41A20310 1020L41A20321 0053R12B10PNF ABS638A12 NSA938151PA2000 0-211-000602000 14-32280-8P6 MS25237-387 14-32280-8P6 MS25237-387 14-32280-8P6 MS25237-387 MS27406-1 BACC18Z2R BACC18Z2R A4123100 A2623630 68-2148 0053R14B19PNF ABSO638B14
BLANK BLANK
BLANK
BLANK
25-05-04
PAGE NOV
198.2 29/07
ITEM continued 352 353 354 355 356 357 358 THRU 359 360 361 362 BLANK 363 364 365 THRU 369 370 370A 371 372 373 THRU 374 375 376 THRU 379 380 381 BLANK 382 383 384 385 BLANK 386 387 388 389 390 THRU 599 600 601 602 603 THRU 610 611 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK
PLUG SPRING LATCH FASTEN TAP HOUSING WIRE WIRE RECEPTACLE GROMMET NUT MOUNTING BRACKET
1 2 2 2 AR AR 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 2 1
0237E09S03A ABS0656A1B1 170-324-2 ABS0374B ASNE0272TK22 ASNE0264PF22 BACC45FT12-12PN 610ES012C12 0-211-000602000 ABS0364A10SC ABS0364B10PC ABS0364C 5001L11A203101 ABS0364C BACC18Z2R 68-2148 A2623630 A4123100 EN3646A01412AN ABS0638A14 NSA938151PA2000 0-211-009204000 MS27212-2-4 MS18029-2S4 MS25226-4-2 MS27212-2-5
BLANK
BLANK BLANK
RECEPTACLE PLUG CABLE BRACKET CONSOLE CABLE BRACKET CIRCUIT BREAKER ROTARY SWITCH KNOB COVER RECEPTACLE GROMMET NUT PIN MOUNTING BRACKET TERMINAL BOARD COVER TERMINAL BUS TERMINAL BOARD
BLANK
BLANK
25-05-04
PAGE NOV
198.3 29/07
ITEM continued 612 613 614 615 THRU 699 700 701 702 THRU 703 704 705 BLANK 706 707 THRU 713 714 715 THRU 729 730 731 732 733 THRU 739 740 741 742 THRU 749 750 751 THRU 759 760 761 762 763 764 765 766 767 THRU 789 790 791 792 793 794 795 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK BLANK
TERMINAL BUS TERMINAL BUS COVER WIRE WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE SPACER CLAMP CLAMP WASHER CONDUIT CONDUIT CONDUIT CONDUIT CONDUIT CONDUIT CONDUIT SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE SLEEVE
1 1 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR
MS25226-4-2 MS25226-4-3 MS18029-2S5 EN2267-008A090P EN2267-008A051P EN2267-008A012P EN2267-008A006P EN2714-011D006F 00-1427 1032 1036L00A21320 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 NSA935805-10 NSA935805-14 NSA935805-16 NSA935805-20 NSA935805-32 NSA937201MA0401 NSA937201MA0403 NSA937201MA0402 NSA937201MA0801 NSA937201MA0803 NSA937201MA0802
BLANK BLANK
BLANK BLANK BLANK
BLANK
25-05-04
PAGE NOV
198.4 29/07
ITEM continued 796 THRU 800 801 802 803 THRU 804 805 806 807 808 THRU 809 810 811 812 813 814 815 816 817 818 819 820 821 822 823 824 825 826 827 828 THRU 829 830 831 832 833 834 835 836 837 838 THRU 839 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK BLANK
GROUND STUD GROUND STUD GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND STUD BRACKET STUD STUD STUD STUD STUD STUD STUD STUD STUD STUD BRACKET STUD STUD STUD STUD STUD STUD STUD STUD BRACKET STUD STUD STUD STUD STUD STUD STUD
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
5026-02-0016 5026-02-0016 0-212-000101000 00-1433 00-882 0-212-000202000 00-1433 00-1433 00-1433 00-882 00-882 5026-02-0008 00-882 5026-02-0008 00-882 0-212-000202000 00-1433 00-1433 00-1433 00-882 00-882 00-882 5026-02-0008 0-212-000202000 00-1433 00-1433 00-1433 00-882 00-882 00-882 5026-02-0008
BLANK
BLANK
BLANK
25-05-04
PAGE NOV
198.5 29/07
25-05-04
PAGE NOV
198.6 29/07
ITEM continued 840 841 842 843 BLANK 844 845 846 THRU 849 850 851 852 THRU 870 871 872 BLANK 873 874 875 THRU 880 881 882 883 884 THRU 889 890 891
NOMENCLATURE
QTY
PART NUMBER
GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD MOUNTING BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD TERMINAL LUG GROUND STUD BRACKET GROUND STUD
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
0-212-000202000 00-1433 00-1433 5026-02-0009 00-882 00-882 1027L41A20350 00-882 00-1472 00-1472 5026-02-0016 5026-02-0016 131149-1 0-212-000101000 00-1433
BLANK BLANK
BLANK
BLANK
25-05-04
PAGE NOV
198.7 29/07
25-05-04
PAGE NOV
198.8 29/07
25-05-04
PAGE NOV
198.9/198.10 29/07
25-05-04
PAGE NOV
198.11/198.12 29/07
25-05-04
PAGE NOV
198.13/198.14 29/07
25-05-04
PAGE NOV
198.15/198.16 29/07
25-05-04
PAGE NOV
198.17/198.18 29/07
APPLICABLE TO WIRING DIAGRAM FIG 134 SH 4 ITEM 1 THRU 9 BLANK 10 11 THRU 19 BLANK 20 21 22 23 24 25 26 27 THRU 29 BLANK 30 31 32 33 THRU 160 BLANK 160A 161 162 THRU 164 BLANK 165 166 THRU 199 BLANK 200 201 202 THRU 699 BLANK 700 701 702 THRU 704 BLANK 705 706 707 708 THRU 712 BLANK 713 714 THRU 729 BLANK 730 731 732 THRU 739 BLANK 740 741 continued NOMENCLATURE QTY PART NUMBER
CONDUIT WORK LIGHT JIFFY JUNCTION PIN PIN JIFFY JUNCTION PIN JIFFY JUNCTION WORK LIGHT JIFFY JUNCTION PIN PLUG CONSOLE CABLE BRACKET WIRE BUNDLE BRACKET WIRE WIRE WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP
AR 1 1 4 3 1 3 1 1 1 4 1 1 1 1 1 AR AR AR AR AR AR AR AR AR AR
NSA935805-9 ML0975-600 111920302 NSA937910EA2000 NSA937910EA2000 111922402 NSA937910EA2000 111922402 ML0975-600 111920302 NSA937910EA2000 ABS0364B10PC 5001L11A203101 ABS0364C RDAM7662-03 0-212-001300000 EN2267-008A090P EN2267-008A051P EN2267-008A010P EN2267-008A006P EN2267-008A004P ASNE0264PF22 00-1427 1032 BACC10GE NSA935807
WIRING DIAGRAM - ELECTRICAL COMPONENTS BAR UNIT G4AFIGURE 134 SH 1 OF 4
25-05-04
PAGE NOV
198.19 29/07
25-05-04
PAGE NOV
198.20 29/07
ITEM continued 742 THRU 749 750 751 THRU 759 760 761 762 763 THRU 799 800 801 802 803 THRU 809 810 811 812 813 THRU 814 815 816 817 THRU 889 890 891
NOMENCLATURE
QTY
PART NUMBER
BLANK BLANK
WASHER CONDUIT CONDUIT CONDUIT GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD
AR AR AR AR 1 1 1 1 1 1 1 1 1 1
NSA935808-01 NSA935805-06 NSA935805-09 NSA935805-10 0-212-000202000 00-1433 00-1433 0-212-000202000 00-1433 00-1433 5026-02-0009 00-1433 5026-02-0016 00-1516
BLANK
BLANK
BLANK BLANK
WIRING DIAGRAM - ELECTRICAL COMPONENTS BAR UNIT G4AFIGURE 134 SH 2 OF 4
25-05-04
PAGE NOV
198.21 29/07
25-05-04
PAGE NOV
198.22 29/07
WIRING DIAGRAM BAR UNIT G4AFIGURE 134 SH 4 OF 4
25-05-04
PAGE NOV
198.23/198.24 29/07
APPLICABLE TO WIRING DIAGRAM FIG 135 SH 4 ITEM 1 THRU 10 BLANK 10A 11 12 13 14 THRU 19 BLANK 20 21 22 23 24 25 26 THRU 199 BLANK 200 201 202 THRU 699 BLANK 700 701 702 THRU 705 BLANK 706 707 THRU 729 BLANK 730 731 732 THRU 739 BLANK 740 741 742 THRU 749 BLANK 750 751 THRU 759 BLANK 760 761 762 THRU 786 BLANK 787 788 789 790 THRU 809 BLANK 810 continued NOMENCLATURE QTY PART NUMBER
PLUG CABLE BRACKET PIN CONSOLE MICRO SWITCH MOUNTING PLATE COVER JIFFY JUNCTION PIN SPOT LIGHT WIRE BUNDLE BRACKET WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP WASHER CONDUIT CONDUIT COVER COVER COVER GROUND STUD BRACKET
1 1 2 1 1 1 1 1 5 1 1 1 AR AR AR AR AR AR AR AR AR AR 1 1 1 1
ABS0364B10PC ABS0364C EN3155-018M2018 5001L11A203101 4BR510 0-211-008400000 0-211-010100000 111922402 NSA937910EA2000 LD0100-010 RDAM7662-03 0-212-001300000 EN2267-008A090P EN2267-008A051P EN2267-008A006P 00-1427 1032 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 0-211-006300001 0-211-006300002 0-211-006300003 0-212-000202000
WIRING DIAGRAM - ELECTRICAL COMPONENTS RH CLOSETFIGURE 135 SH 1 OF 4
25-05-04
PAGE NOV
198.25 29/07
25-05-04
PAGE NOV
198.26 29/07
ITEM continued 811 812 813 THRU 829 BLANK 830 831 832
NOMENCLATURE
QTY
PART NUMBER
GROUND STUD GROUND STUD GROUND STUD GROUND STUD GROUND STUD
1 1 1 1 1
00-1433 00-1433 5026-02-0016 00-1516 0-212-002900000
WIRING DIAGRAM - ELECTRICAL COMPONENTS RH CLOSETFIGURE 135 SH 2 OF 4
25-05-04
PAGE NOV
198.27 29/07
25-05-04
PAGE NOV
198.28 29/07
WIRING DIAGRAM RH CLOSETFIGURE 135 SH 4 OF 4
25-05-04
PAGE NOV
198.29/198.30 29/07
APPLICABLE TO WIRING DIAGRAM FIG 136 SH 3 ITEM 1 200 201 202 700 701 702 706 707 730 731 732 740 741 742 750 751 760 761 762 787 788 789 790 810 811 812 813 830 831 THRU 199 BLANK THRU 699 BLANK THRU 705 BLANK THRU 729 BLANK THRU 739 BLANK THRU 749 BLANK THRU 759 BLANK THRU 786 BLANK NOMENCLATURE QTY PART NUMBER
WIRE BUNDLE BRACKET WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP WASHER CONDUIT CONDUIT COVER COVER COVER GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD GROUND STUD
1 1 AR AR AR AR AR AR AR AR AR AR 1 1 1 1 1 1 1 1
RDAM7662-03 0-212-001300000 EN2267-008A090P EN2267-008A051P EN2267-008A006P 00-1427 1032 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 0-211-006300001 0-211-006300002 0-211-006300003 0-212-000202000 00-1433 00-1433 5026-02-0016 00-1516
THRU 809 BLANK
THRU 829 BLANK
WIRING DIAGRAM - ELECTRICAL COMPONENTS RH COAT CLOSET DOOR 2FIGURE 136 SH 1 OF 3
25-05-04
PAGE NOV
198.31 29/07
25-05-04
PAGE NOV
198.32 29/07
WIRING DIAGRAM RH COAT CLOSET DOOR 2FIGURE 136 SH 3 OF 3
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APPLICABLE TO WIRING DIAGRAM FIG 137 SH 4 ITEM 1 THRU 108 109 110 BLANK 110A 111 112 113 114 115 116 THRU 150 150A 151 152 THRU 159 160 161 162 THRU 650 650A 651 652 653 654 THRU 700 701 702 THRU 704 705 706 707 708 THRU 714 715 716 THRU 729 730 731 732 THRU 739 740 741 742 THRU 749 750 751 THRU 759 continued BLANK NOMENCLATURE QTY PART NUMBER
CONDUIT PLUG BACKSHELL SPRING LATCH JIFFY JUNCTION PIN SOCKET PLUG CABLE BRACKET CONTACT HOUSING PLUG CABLE BRACKET PIN SOLDERING SLEEVE WIRE WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP WASHER
AR 1 1 2 1 4 8 1 1 2 2 1 1 6 1 AR AR AR AR AR AR AR AR AR AR
NSA935805-9 0237E15S03A 8630-26B ABS0656A1B1 111922202 NSA937910EA2000 ASNE0396DV2001 ABS0364B10P ABS0364C ABS0374A24 ABS0374B ABS0364B10PC ABS0364C EN3155-018M2018 D101-31 EN2267-008A051P EN2267-008A010P EN2267-008A006P EN2267-008A004P ASNE0272TK22 00-1427 1032 BACC10GE NSA935807 NSA935808-01
BLANK BLANK BLANK
BLANK BLANK
BLANK BLANK BLANK BLANK BLANK
WIRING DIAGRAM - ELECTRICAL COMPONENTS AFT PARTITIONFIGURE 137 SH 1 OF 4
25-05-04
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25-05-04
PAGE NOV
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ITEM continued 760 761 762 763 THRU 800 BLANK 801 802 803 THRU 810 BLANK 811 812
NOMENCLATURE
QTY
PART NUMBER
CONDUIT CONDUIT CONDUIT GROUND STUD BRACKET GROUND STUD GROUND STUD GROUND STUD
AR AR AR 1 1 1 1
NSA935805-06 NSA935805-09 NSA935805-10 0-212-000101000 00-1433 00-882 00-882
WIRING DIAGRAM - ELECTRICAL COMPONENTS AFT PARTITIONFIGURE 137 SH 2 OF 4
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25-05-04
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WIRING DIAGRAM AFT PARTITIONFIGURE 137 SH 4 OF 4
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APPLICABLE TO WIRING DIAGRAM FIG 138 SH 4 ITEM 1 THRU 209 210 211 211A 212 213 214 215 THRU 219 220 221 221A 222 223 224 225 THRU 229 230 231 231A 232 233 234 235 THRU 239 240 241 241A 242 243 244 245 THRU 510 510A 511 THRU 513 514 515 THRU 530 530A 531 THRU 533 534 535 THRU 700 continued BLANK NOMENCLATURE QTY PART NUMBER
BLANK
FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET PLUG CABLE BRACKET PLUG CABLE BRACKET
1 1 1 1 4 2 1 1 1 1 4 2 1 1 1 1 4 2 1 1 1 1 4 2 1 1 1 1
ABS1238-26-15B 4197-10-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 ABS1238-26-15B 4197-10-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 ABS1238-26-15B 4197-10-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 ABS1238-26-15B 4197-10-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 ABS0364B26P ABS0364C ABS0364B26P ABS0364C
BLANK
BLANK
WIRING DIAGRAM - ELECTRICAL COMPONENTS PELMET UNIT G3/G4FIGURE 138 SH 1 OF 4
25-05-04
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25-05-04
PAGE NOV
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ITEM continued 701 702 THRU 703 704 705 706 707 708 THRU 712 713 714 THRU 729 730 731 732 THRU 739 740 741 742 THRU 749 750 751 THRU 759 760 761 762 763 764 THRU 919 920 921 THRU 939 940
NOMENCLATURE
QTY
PART NUMBER
BLANK
WIRE WIRE WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP WASHER CONDUIT CONDUIT CONDUIT CONDUIT GROUND STUD GROUND STUD
AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 1 1
EN2267-008A051P EN2267-008A012P EN2267-008A010P EN2267-008A006P EN2267-008A004P ASNE0264PF22 00-1427 1032 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 NSA935805-10 NSA935805-14 00-882 00-882
BLANK BLANK
25-05-04
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25-05-04
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WIRING DIAGRAM PELMET UNIT G3/G4FIGURE 138 SH 4 OF 4
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APPLICABLE TO WIRING DIAGRAM FIG 139 SH 6 ITEM 1 2 3 4 5 THRU 29 30 31 31A 32 33 34 35 36 THRU 39 40 41 41A 42 43 44 45 46 THRU 49 50 51 51A 52 53 54 55 56 THRU 59 60 61 61A 62 63 64 65 66 THRU 69 continued NOMENCLATURE RECEPTACLE GROMMET NUT MOUNTING BRACKET MOUNTING BRACKET FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET GROUND STUD FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET GROUND STUD FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET GROUND STUD FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET GROUND STUD QTY 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 4 2 1 1 1 1 1 4 2 1 1 1 1 1 4 2 1 PART NUMBER 0053R20B41PNF ABS0638C20 1018L49A20335 1018L49A20330 ABS1238-26-30B 4197-20-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 00-882 ABS1238-26-15B 4197-10-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 00-882 ABS1238-26-30B 4197-20-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 00-882 ABS1238-26-15B 4197-10-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 00-882
BLANK
BLANK
BLANK
BLANK
BLANK
25-05-04
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ITEM continued 70 71 71A 72 73 74 75 76 THRU 79 BLANK 80 81 82 83 84 85 THRU 99 BLANK 100 101 102 THRU 109 BLANK 110 111 112 113 114 BLANK 115 116 117 THRU 119 BLANK 120 121 122 123 124 THRU 129 BLANK 130 131 132 133 134 135 THRU 149 BLANK continued
NOMENCLATURE
QTY
PART NUMBER
FLUORESCENT TUBE BALLAST UNIT PLUG BACKSHELL SOCKET SOCKET GROUND STUD RAIL END CLAMP BRACKET TERMINAL BLOCK TERMINAL BLOCK CONTACT HOUSING RECEPTACLE CABLE BRACKET CONSOLE MOUNTING BRACKET TERMINAL BLOCK TERMINAL BLOCK RECEPTACLE CABLE BRACKET CONSOLE MOUNTING BRACKET RECEPTACLE CABLE BRACKET CONSOLE MOUNTING BRACKET SOLDERING SLEEVE
1 1 1 1 4 2 1 1 2 1 1 1 6 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2
ABS1238-26-15B 4197-10-02 ABS1019-003ASC ABS1019-005A ASNE0396DV2200 ASNE0396DV2001 00-882 NSA937901R100 NSA937901S 1033L44A20350 NSA937901M2002 NSA937901M2002 ABS0374A24 ABS0374B ABS0364A26SC ABS0364C 5001L11A203101 1006L49B20330 NSA937901M2011 NSA937901M2008 ABS0364A26SC ABS0364C 5001L11A203101 1006L49B20330 ABS0364A26SC ABS0364C 5001L11A203101 1006L49B20330 D101-31
25-05-04
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ITEM continued 150 151 152 153 154 THRU 209 210 211 THRU 219 220 221 THRU 229 230 231 THRU 239 240 241 THRU 360 360A 361 362 THRU 700 701 702 THRU 704 705 706 707 708 THRU 711 712 713 714 THRU 729 730 731 732 THRU 739 740 741 742 THRU 749 750 751 THRU 759 760 761 762 continued
NOMENCLATURE
QTY
PART NUMBER
BLANK BLANK BLANK BLANK BLANK BLANK BLANK
RECEPTACLE CABLE CLAMP CONSOLE MOUNTING BRACKET TERMINAL BLOCK TERMINAL BLOCK TERMINAL BLOCK TERMINAL BLOCK PLUG CLAMP WIRE WIRE WIRE WIRE WIRE WIRE DISTANCE SLEEVE DISTANCE SLEEVE CLAMP CLAMP WASHER CONDUIT CONDUIT CONDUIT
1 1 1 1 1 1 1 1 1 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR
ABS0364A10SC ABS0364C 5001L11A203101 1006L49B20330 NSA937901M2002 NSA937901M2002 NSA937901M2002 NSA937901M2002 BACC45FT12-12SN NSA938112-12C01 EN2267-008A051P EN2267-008A010P EN2267-008A006P EN2267-008A004P ASNE0274PF24 ASNE0264PF22 00-1427 1032 BACC10GE NSA935807 NSA935808-01 NSA935805-06 NSA935805-09 NSA935805-10
25-05-04
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25-05-04
PAGE NOV
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ITEM continued 763 764 THRU 799 BLANK 800 801 802 THRU 804 BLANK 805
NOMENCLATURE
QTY
PART NUMBER
CONDUIT TERMINAL LUG TERMINAL LUG GROUND STUD
AR 1 1 1
NSA935805-14 50846 50846 00-882
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WIRING DIAGRAM PELMET UNIT G6/G7FIGURE 139 SH 6 OF 6
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5.
WATER INSTALLATION A. B. This chapter provides information about typical failure symptoms and trouble shooting. Visual Check (1) (2) (3) C. Check hoses, tubes and connections for aging and signs of leakage. Check spigots and valves for proper action and tightness. Check tightness of water system using a test pressure of 125 psi (8.62 bar).
Test Procedure
Galley water system is connected to airplane supply.
Beverage maker, espresso maker or hot jug does not fill. Cold water spigot does not operate.
Beverage maker, espresso maker or hot jug drip pan overflows.
Check airplane supply. Check galley shut off valve. Check beverage maker, espresso maker or hot jug filling valve.
Check for blocked or distored waste water line.
Check water installation lines for distortion or leakage.
Beverage maker, espresso maker or hot jug does not fill. Replace beverage maker, espresso maker or hot jug.
Fault corrected.
TEST PROCEDURE, WATER INSTALLATION FIGURE 140
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D I S A S S E M B L Y
1.
GENERAL A. Overhaul procedures are normally performed by overhaul shop mechanics. Partial overhaul and repair may be performed without removing the galley units from the airplane. NOTE: See chapter TESTING AND FAULT ISOLATION to establish the condition of the component or most probable cause of its malfunction. This is to determine the extent of disassembly required without completely tearing down and rebuilding the component. B. Complete disassembly is neither required nor desired. Disassemble only to the extent required to make necessary repairs or replacements. NOTE: Carefully inspect all riveted, screwed and bonded assemblies and components prior to disassembly. Do not disassemble unless damaged. C. In the following instructions, do not disassemble components which are found through inspection to be in good condition, unless their removal is necessary to gain access to a damaged part. Proceed with disassembly in the general order of key index numbers assigned to the exploded view illustration in the ILLUSTRATED PARTS CATALOG (IPC), noting that attaching parts immediately follow the part they attach. NOTE: In the following disassembly procedures, when an item number is given without a figure number, the last preceding IPC figure number reference applies.
D.
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2.
GALLEY UNIT G1, G2, G3, G4, G5, G6, G7, BAR UNIT G4A, RH CLOSET UNIT AND RH COAT CLOSET UNIT - DISASSEMBLY NOTE: Check that all equipment is removed from galley units. NOTE: For illustrations and item numbers refer ILLUSTRATED PARTS CATALOG 25-05-04. NOTE: For compartment numbers refer chapter DESCRIPTION AND OPERATION. NOTE: If bumpers and sliding strips showing wear of 50% refer chapter CHECK para. 2.F. A. Pelmet Units G3/G4 And G6/G7 Assemblies (1) Pelmet unit G3/G4 assy (refer IPC, fig 2) (a) (b) Disconnect electrical system (5) from airplane supply system. Removal of ceiling panel assemblies (10, 25) 1 Remove ceiling panel assemblies (10, 25) from pelmet assy (-1). 2 Remove extrusions (15, 30) from ceiling panel assemblies (10, 25). 3 Pull off velcros (20, 35) from ceiling panel assemblies (10, 25) in case of damage only. (c) Removal of ceiling panel assemblies (40, 55) 1 Remove ceiling panel assemblies (40, 55) from pelmet assy. 2 Remove extrusions (45, 60) from ceiling panel assemblies (40, 55). 3 Pull off sealing profiles (50, 65) from ceiling panel assemblies (40, 55) in case of damage only. (d) Removal of ceiling panel assy (70) 1 Remove pan-head screws (115), washers (120) and ceiling panel assy (70) from pelmet assy. 2 Remove extrusion (75) from ceiling panel assy (70). 3 Remove pan-head screws (85) and exhaust hood (80) from ceiling panel assy (70).
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4 Removal of air screen assy (95) a Loosen fasteners (-110) and remove air screen assy (95) from ceiling panel assy (70). b Remove fasteners (-110), retainer (-100) and filter pad (-105) from air screen assy (95). 5 Pull off sealing profile (90) from ceiling panel assy (70) in case of damage only. (e) Removal of pelmet assemblies (150, 180, 210, 240) 1 Remove pelmet assemblies (150, 180, 210, 240) from pelmet assy. 2 Remove pan-head screws (160, 170, 190, 200, 220, 260, 250, 260) and brackets (155, 165, 185, 195, 215, 225, 245) from pelmet assemblies (150, 180, 210, 240). 3 Pull off velcros (175, 205, 235, 265) from pelmet assemblies (150, 180, 210, 240) in case of damage only. (f) Removal of ceiling panel assemblies (270, 290, 310, 325, 340, 360) 1 Remove closing caps (285, 305, 320, 335, 355, 375) from ceiling panel assemblies (270, 290, 310, 325, 340, 355). 2 Remove ceiling panel assemblies (270, 290, 310, 325, 340, 355) from pelmet assy. 3 Pull off velcros (275, 295, 315, 330, 345, 365) and sealing profiles (280, 300, 370) from ceiling panel assemblies (270, 290, 310, 325, 340, 360) in case of damage only. (g) Removal of support assemblies (380, 425) 1 Remove support assemblies (380, 425) from pelmet assy. 2 Remove countersunk screws (405, 450), extrusions (390, 435) and sealing profiles (400, 445) from support assy (380, 425). 3 Remove pan-head screws (415, 460), supports (410, 455) and shims (420, 465) from support assy (380, 425). 4 Pull off velcros (395, 440) and sealing profiles (385, 430) from support assemblies (380, 425) in case of damage only.
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(h)
Removal of support assemblies (470, 480) 1 Remove support assemblies (470, 480) from pelmet assy. 2 Pull off sealing profiles (475, 485) from support assemblies (470, 480) in case of damage only.
(j)
Removal of bar assy (490) 1 Remove bar assy (490) from pelmet assy. 2 Pull off sealing profiles (495, 500) from bar assy (490) in case of damage only.
(k) (l) (m) (2)
Remove countersunk screws (145) and work light cover (140) from pelmet assy. Remove pan-head screws (130), washers (135) and work light casing (125) from pelmet assy. Pull off sealing profile (505) from pelmet assy in case of damage only.
Pelmet unit G6/G7 assy (refer IPC, fig 2A) (a) Removal of ceiling panel assy (5) 1 Disconnect electrical system (310) from airplane supply system. 2 Loosen fasteners (250) and remove ceiling panel assemblies (5, 130) from pelmet assy (-1). 3 Remove fasteners (250) and spacers (245, 290) from ceiling panel assy (5). 4 Removal of lens assemblies (30, 50) a Loosen fasteners (45, 65) and remove lens assemblies (35, 50) from ceiling panel assy (5). b Remove fasteners (45, 65) from lenses (35, 50). c Pull off adhesive foils (40, 60) from lens assemblies (30, 35) in case of damage only. 5 Loosen fasteners (125) and remove pan-head screws (20), washers (25) and lamp casings (10, 15) from ceiling panel assy (5). 6 Remove fasteners (125) from lamp casings (10, 15).
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7 Remove pan-head screws (110), washers (25), extrusions (75, -80, -85, 90) and spacers (95) from ceiling panel assy (5), 8 Drill out countersunk rivets (120) and remove extrusions (100, -105) from extrusion (90). 9 Remove extrusion (70) from ceiling panel assy (5). 10 Pull off sealing profile (115) from ceiling panel assy (5) in case of damage only. (b) Removal of ceiling panel assy (130) 1 Loosen fasteners (250) and remove ceiling panel assy (130) from pelmet assy. 2 Removal of lens assy (155) a Loosen fasteners (170) and remove lens assy (155) from ceiling panel assy (130). b Remove fasteners (170) from lens (160). c Pull off adhesive foil (165) from lens assy (130) in case of damage only. 3 Loosen fasteners (150) and remove pan-head screws (140), washers (145) and lamp casing (135) from ceiling panel assy (130). 4 Remove fasteners (150) from lens (160). 5 Remove pan-head screws (220), washers (145), extrusions (-175, 180, -185, 190, 195) and spacers (210, 215) from ceiling panel assy (130). 6 Drill out countersunk rivets (235) and remove extrusions (200, -205) from extrusion (190, -185). 7 Pull off sealing profiles (225, -230) from ceiling panel assy (130) in case of damage only. (c) (d) (e) (f) Remove pan-head screws (260) and bars (240) from supports (255). Remove pan-head screws (265), washers (270) and supports (255) from galley units G6 and G7. Remove pan-head screws (280), bar (240) and spacer (275) from galley units G6 and G7. Pull off sealing profiles (295, 300, 305) from pelmet assemblies (5, 130).
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B.
Galley Units G1, G2, G3, G4, G5, G6, G7, G4A, RH Closet And AFT Partition - Structure Assemblies (1) Galley unit G1 Structure assy (a) Removal of steam ovens (refer IPC, fig 3) 1 Remove cover caps (575, fig 6) from structure assy (5). 2 Remove pan-head screws (35), washers (40) and steam ovens from compartments 104 and 105. (b) Removal of refrigerator 1 Remove pan-head screws (35), washers (40) and refrigerator from compartment 106. (c) Removal of beverage maker 1 Remove beverage maker from compartment 107. (d) (e) (f) (g) Remove mirror (45) from structure assy (5). Remove countersunk screws (55) and paper clip (50) from structure assy (5). Remove pan-head screws (65) and cup holder (60) from structure assy (5). Remove pan-head screws (90), washers (95), pip-pins (80, -110) with securing ropes (85) and tie rods (70, -75) from upper attachment brackets (485, fig 6; 635, fig 6). Remove single revolving catches (40, 45) from structure assy (-1) (refer IPC, fig 4). Remove pan-head screws (70, 75) and single revolving catches (65, 80) from structure assy. Remove countersunk screws (60), spacers (50) and bumpers (55) from structure assy. Separation of lower part assy (5) and upper part assy (10) 1 Disconnect electrical system (10, fig 3), water installation assy (15, fig 3) and ventilation system (20, fig 3) between structure parts and airplane supply systems. 2 Remove decorative materials (30, fig 3).
(h) (i) (j) (k)
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3 Remove joint covers (525, fig 6) from structure assy. 4 Remove allen screws (15, 20), pan-head screws (35), special nuts (25), washers (30) and upper part assy (10) from lower part assy (5). (2) Galley unit G2 Structure assy (a) Removal of microwave oven (refer IPC, fig 3A) 1 Remove countersunk screws (75) and microwave oven from compartment 205. (b) (c) (d) Remove hexagonal screw (40), hexagonal nut (50), washers (45) and tie rod (35) from upper attachment assy (225, fig 4A). Remove pan-head screw (65), washer (70), pip-pin (55) with securing rope (60) and tie rod (35) from upper attachment assy (190, fig 4A). Removal of insulated folding door assemblies (5, 15) (refer IPC, fig 4A). 1 Remove pan-head screws (10, 20) and insulated folding door assemblies (5, 15) from structure assy (-1). (e) Removal of door assemblies (25, 35) 1 Remove pan-head screws (30, 40) and door assemblies (25, 35) from structure assy. (f) Removal of drawer assy (45) 1 Pull drawer assy (45) to stop, push arresting button and withdraw drawer assy (45) from rail guides (65, fig 17A). 2 Remove countersunk screws (70 , fig 17A) and rail guides (65, fig 17A) from structure assy. (g) Removal of sliding work table assemblies (50, 65) NOTE: Prior to release the pan of sliding work table, make sure, that the attachment screws have been entirely pulled downwards and a minimum space 8,0 mm (0.32) between the upper surface of the fastener and the surface of the shell is granted. These can be checked e.g. with fingertip. 1 Loosen retainers (55, 65) and remove sliding work table assemblies (50, 60) from structure assy. 2 Remove retainers (55, 65) from structure assy.
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(h)
Removal of guide assemblies (90, 100, 110, -120) 1 Remove pan-head screws (140), washers (140) and guide assemblies (90, 100, 110, -120) from structure assy. 2 Pull off sliding strips (95, 105, 115, -125) from guide assemblies (90, 100, 110, -120) in case of damage only.
(i) (j)
Remove extrusions (135) and sealing profiles (130) from structure assy. Removal of door holder assy (150) 1 Remove pan-head screws (180), washers (185) and door holder assy (150). 2 Remove screws (-175), brackets (-160, -165) and shim (-170) from gas spring cylinder (-155).
(k)
Removal of upper attachment assemblies (190, 225) 1 Remove hexagonal screws (195, 210, 230, 245), hexagonal nuts (205, 220, 240, 250), washers (200, 215, 235, 255) and upper attachment assemblies (190, 225) from upper attachment brackets (430) and from extrusions (445).
(l)
Removal of sink assy (260) 1 Remove pan-head screws (275), washers (280) and sink assy (260) from structure assy. 2 Remove pan-head screws (-270) and sieve (-265) from sink assy (260).
(m)
Removal of disengaging installation assy (285) 1 Remove pan-head screws (295), countersunk screws (305), threaded bushings (290), bushings (300) and disengaging installation assy (285).
(n)
Removal of cover assy (545) 1 Remove pan-head screws (295), washers (145) and cover assy (545) from structure assy. 2 Pull off sealing profile (550) and plate (555) from cover assy (545) in case of damage only.
(o)
Removal of cover assy (575) 1 Remove countersunk screws (305), pan-head screws (295), washers (145) and cover assy (575) from structure assy.
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2 Pull off sealing profile (-580), sliding strip (-585) and plate (-590) from cover assy (575) in case of damage only. (p) Removal of revolving catch assy (605) 1 Remove slotted pin (35, fig 21), knob (60, fig 21) and distance bushing (20, fig 21) from axle (10, fig 21). 2 Remove pan-head screws (610) and support (5, fig 21) with axle (10, fig 21) from structure assy. 3 Remove setscrew (45, fig 21), ball catch (30, fig 21), axle (10, fig 21), bushing (40, fig 21), revolving catch (15, fig 21), lock washer (55, fig 21), washer (50, fig 21) and distance bushing (25, fig 21) from support (5, fig 21). (q) Removal of revolving catch assy (630) 1 Remove countersunk screws (20, fig 21A) and cover (25, fig 21A) from support (5, fig 21A). 2 Remove setscrew (60, fig 21A), ball catch (40, fig 21A), axle (10, fig 21A) with knob (30, fig 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) from support (5, fig 21A). 3 Remove slotted pin (35, fig 21A), washer (15, fig 21A) and knob (30, fig 21A) from axle (10, fig 21A). 4 Remove pan-head screws (710) and support (5, fig 21A) from structure assy. 5 Remove bushings (55, fig 21A; 65, fig 21A) from support (5, fig 21A). (r) Removal of roller blind installation assy (670) 1 Remove pan-head screws (700), washers (705) and roller blind installation assy (670) from structure assy. 2 Removal of support assy (675) a Loosen fasteners (680) and remove support assy (675) from roller blind installation assy (670). b Remove fasteners (680) from support assy (675). 3 Remove countersunk screws (695) and loop (685) from roller blind installation assy (670).
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4 Remove countersunk screws (695) and grips (690) from roller blind installation assy (670). (s) (t) (u) (v) (w) (x) (y) (z) (za) (zb) (zc) Remove work counter top (70) from structure assy. Remove pan-head screws (140), extrusions (75) and shims (80) from structure assy. Remove countersunk screws (85, 390) and strikes (565) from structure assy. Remove countersunk screws (315) and spacers (310) from structure assy. Remove countersunk screws (325) and guide (320) from structure assy. Remove pan-head screws (140), washers (145), extrusions (330, 335, 340, 375), air grids (-350, 355) and sealing profile (370) from structure assy. Remove countersunk screws (315), spacers (365) and bumpers (360) from structure assy. Remove countersunk screws (280, 390) and extrusions (380, 385) from structure assy. Remove pan-head screws (405, 410), single revolving catches (395, 400) and double revolving catch (425) from structure assy. Remove single revolving catches (415, 420) from structure assy. Remove hexagonal screws (435), countersunk screws (460), hexagonal nuts (450), washers (440, 455), extrusions (445) and upper attachment brackets (430) from structure assy. Remove hexagonal screws (470), washers (475) and supports (465) from structure assy. Remove pan-head screws (140) and bracket (480) from structure assy. Remove pan-head screws (500), washers (145) and brackets (485, 490, -495) from structure assy. Remove countersunk screws (510), cover (505) and air grid (560) from structure assy. Remove countersunk screws (305, 325), pan-head screws (540), washers (475) and lower attachment brackets (535, 570) from structure assy. Remove pan-head screws (140) and extrusion (600) from structure assy. Remove countersunk screws (620) and guides (615) from structure assy.
(zd) (ze) (zf) (zg) (zh) (zi) (zj)
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(zk) (zl) (zm)
Remove countersunk screws (315) and extrusion (625) from structure assy. Remove pan-head screws (140), washers (145), extrusion (660) and shims (650, 655) from structure assy. Pull off extrusions (-345, -665), bumpers (515, 520), shims (525, 530, 645), guides (595) and sliding strips (640) from structure assy in case of damage only.
(3)
Galley unit G3 Structure assy (a) (b) Disconnect electrical system (-10), water installation assy (15) and cooling system (20) from airplane supply systems (refer IPC, fig 3B). Remove pan-head screws (200), washers (205), pip-pin (190) with securing ropes (195) and tie rods (185) from upper attachment assy (65) (refer IPC, fig 4B). Removal of door holder assy (505) 1 Open doors (45, 55) and remove countersunk screws (525), pan-head screws (545), washers (535), spacers (515) and door holder assy (505) from doors (45, 55) and from structure assy (-1) 2 Remove pan-head screws (530), hexagonal nuts (540), washers (550) and brackets (520) from retainer (510). (d) Removal of door assemblies (5, 15, 25, 35, 45, 55) 1 Remove countersunk screws (10, 20, 30, 40, 50, 60) and door assemblies (5, 15, 25, 35, 45, 55) from structure assy. (e) Removal of upper attachment assy (65) 1 Remove hexagonal screws (80, 85), hexagonal nuts (70, 90), washers (75, 95) and upper attachment assy (65) from structure assy. (f) Removal of ice drawer assy (100) 1 Pull ice drawer assy (100) to stop, push arresting button and withdraw ice drawer assy (100) from rail guides (55, fig 17). 2 Remove countersunk screws (60 , fig 17) and rail guides (55, fig 17) from structure assy. (g) Removal of guide assemblies (105, 125, 135) 1 Remove pan-head screws (120), guide assemblies (105, 125, 135) and shims (115) from structure assy.
(c)
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2 Pull off sliding strips (110, 130, 140) from guide assemblies (105, 125, 135) in case of damage only. (h) Removal of guide assy (145) 1 Remove pan-head screws (120), shims (115) and guide assy (145) from structure assy. 2 Pull off sliding strips (150) and shims (155) from guide assy (125) in case of damage only. (i) Removal of cover assy (220) 1 Remove countersunk screws (260), pan-head screw (255), washer (175) and cover assy (220) from structure assy. 2 Remove plate (230) from cover assy (220). 3 Pull off sealing profile (225) from cover assy (220) in case of damage only. (j) Removal of cover assy (235) 1 Remove countersunk screws (260), pan-head screws (255), washers (175) and cover assy (235) from structure assy. 2 Pull off sealing profile (240) from cover assy (235) in case of damage only. (k) Removal of cover assy (265) 1 Remove countersunk screws (465) and cover assy (265) from structure assy. 2 Remove pan-head rivets (275) and closing cap (270) from cover assy (265). (l) Removal of drip pan assy (435) 1 Remove drip pan assy (435) from structure assy. 2 Remove countersunk screws (445) and sieve (440) from drip pan assy (435). (m) (n) (o) Remove pan-head screws (170), washers (175), extrusions (165) and sealing profiles (160) from structure assy. Remove single revolving catches (210, 215) from structure assy. Remove countersunk screws (260), pan-head screws (255), washers (175) and cover (245, 250) from structure assy.
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(p) (q) (r) (s) (t) (u) (v) (w) (x) (y) (z) (za)
Remove countersunk screws (555), pan-head screws (560), washers (565) and lower attachment brackets (375, 380, 415) from structure assy. Remove extrusions (185, 390, 395, 200) from structure assy. Remove hexagonal screws (325), washers (330) and upper attachment brackets (315, 320) from structure assy. Remove pan-head screws (350) and extrusions (335, 340, -345) from structure assy. Remove pan-head screws (360), hexagonal nuts (365) and single revolving catches (355) from structure assy. Remove pan-head screws (200), bumpers (370) and shims (575) from structure assy. Remove countersunk screws (405), shims (395, 400) and plate (390) from structure assy. Remove pan-head screws (120) and extrusion (410) from structure assy. Remove countersunk screws (455) and strikes (450, 570) from structure assy. Remove countersunk screws (465) and guides (460) from structure assy. Remove countersunk screws (260) and guide (480) from structure assy. Pull off sliding strips (180, 425, 470, 475, 490, 495, 500), guides (300, 305), shims (310, 385, 420) and bumpers (485) from structure assy in case of damage only.
(4)
Galley unit G4 structure assy (a) Removal of steam oven (refer IPC, fig 3C) 1 Remove pan-head screws (135), washers (140) and steam oven from compartment 404. (b) Removal espresso maker 1 Remove espresso maker from compartment 405. (c) Removal of hot jug 1 Remove hot jug from compartment 406.
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(d)
Removal of beverage maker 1 Remove beverage maker from compartment 407.
(e)
Removal of refrigerator 1 Remove pan-head screws (135), washers (140) and refrigerator from compartment 408.
(f)
Remove countersunk screws (60), washers (65), pip-pins (50) with securing rope (55) and tie rods (45) from upper part assemblies (50, fig 6A) (refer IPC, fig 4C). Removal of cover assemblies (-120, 130, 140) 1 Remove countersunk screws (35, 40) and cover assemblies (-120, 130, 140) from structure assy (-1). 2 Pull off sealing profiles (-125, 135, 145) from cover assemblies (-120, 130, 140) in case of damage only.
(g)
(h)
Removal of roller blind installation assy (-150) 1 Removal of roller blind assy (155) a Remove countersunk screws (190) and roller blind assy (155). b Remove pan-head screws (170) and loop (160) from roller blind assy (155). c Remove pan-head screws (170) and grip (165) from roller blind assy (155). 2 Remove pan-head screws (180), washers (185) and supports (175) from roller blind installation assy (-150).
(i) (j) (k) (l) (m)
Remove countersunk screws (35, 40) and cover (30) from structure assy. Remove pan-head screws (75) and single revolving catches (70) from structure assy. Remove single revolving catches (80, 85) from structure assy. Remove countersunk screws (100), bumpers (90) and spacers (95) from structure assy. Remove pan-head screws (115), extrusion (105) and sealing profile (110) from structure assy.
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(n)
Separation of lower part assy (5) and upper part assy (10) 1 Disconnect electrical system (10, fig 3C), water installation assy (15, fig 3C), ventilation system (20, fig 3C) and cooling system (25, fig 3C) between structure parts and from airplane supply systems. 2 Remove decorative materials (35, fig 3C). 3 Remove joint covers (290 fig 6A, 295, fig 6A) from structure assy. 4 Remove allen screws (15, 25), special nuts (20) and upper part assy (10) from lower part assy (5).
(5)
Galley unit G5 Structure assy (a) (b) (c) Disconnect electrical system (-10) and water installation assy (15) from airplane supply system (refer IPC, fig 3D). Remove decorative materials (25). Remove pan-head screws (45), washers (50), pip-pins (35) with securing rope (40) and tie rods (30) from upper attachment brackets (240, fig 4D) (refer IPC, fig 3D). Remove pan-head screws (60), washers (65) and wine bottle opener (55) from structure assy. Removal of door assy (5) (refer IPC, fig 4D) 1 Remove pan-head screws (10), washers (15) and door assy (5) from structure assy (-1). (f) Removal of door assemblies (20, 35) 1 Remove countersunk screws (25, 40), washers (30, 45) and door assemblies (20, 35) from structure assy. (g) Removal of ice drawer assy (50) 1 Pull ice drawer assy (50) to stop, push arresting button and withdraw ice drawer assy (50) from rail guides (60, fig 17A) in compartments 510 and 511. 2 Remove countersunk screws (65, fig 17A) and rail guides (60, fig 17A) from structure assy.
(d) (e)
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(h)
Removal of sliding work table assy (55) NOTE: Prior to release the pan of sliding work table, make sure, that the attachment screws have been entirely pulled downwards and a minimum space 8,0 mm (0.32) between the upper surface of the fastener and the surface of the shell is granted. These can be checked e.g. with fingertip. 1 Loosen retainer (60) and remove sliding work table assy (55) from structure assy. 2 Remove retainer (60) from structure assy.
(i)
Removal of cover assy (70) 1 Remove cover assy (70) from structure assy. 2 Remove closing cap (75) from cover assy (70). 3 Pull off velcro (80) from cover assy (70) in case of damage only.
(j)
Removal of cover assy (315) 1 Remove countersunk screws (330) and cover assy (315) from structure assy. 2 Remove plate (320) from cover assy (315). 3 Pull off sealing profile (325) from cover assy (315) in case of damage only.
(k)
Removal of cover assy (375) 1 Remove countersunk screws (330) and cover assy (375) from structure assy. 2 Remove spacer (380) from cover assy (375). 3 Pull off sealing profile (385) from cover assy (375) in case of damage only.
(l)
Removal of guide assy (100) 1 Remove pan-head screws (120), washers (125), guide assy (100), extrusions (115) and sealing profiles (110) from structure assy. 2 Pull off sliding strips (105) from guide assy (100) in case of damage only.
(m)
Removal of disengaging installation assy (410)
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1 Remove countersunk screws (160), pan-head screws (420), threaded bushings (415), bushings (425) and disengaging installation assy (410) from structure assy. (n) Removal of revolving catch assy (465) 1 Remove slotted pin (35, fig 21), knob (60, fig 21) and distance bushing (20, fig 21) from axle (10, fig 21). 2 Remove setscrew (45, fig 21), bushing (40, fig 21), revolving catch (15, fig 21), lock washer (55, fig 21), washer (50, fig 21) and distance bushing (25, fig 21) from axle (10, fig 21). 3 Remove ball catch (30, fig 21) and axle (10, fig 21) from support (5, fig 21). 4 Remove countersunk screws (470) and support (5, fig 21) from structure assy. (o) Removal of revolving catch assy (495) 1 Remove countersunk screws (20, fig 21A) and cover (25, fig 21A) from support (5, fig 21A). 2 Remove slotted pin (35, fig 21A), knob (30, fig 21A), spacer (505), washer (15, fig 21A), setscrew (60, fig 21A), bushing (65, fig 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) from axle (10, fig 21A). 3 Remove ball catch (40, fig 21A), bushing (55, fig 21A) and axle (10, fig 21A) from support (5, fig 21A). 4 Remove countersunk screws (500) and support (5, fig 21A) from structure assy. (p) Removal of drip pan assy (525) 1 Remove drip pan assy (525) from structure assy. 2 Remove countersunk screws (-535) and sieve (-530) from drip pan assy (525). (q) (r) (s) Remove countersunk screws (95) and bottle holder (90) from structure assy. Remove pan-head screws (140, 230), washers (125), spacer (135) and table holder (130) from structure assy. Remove countersunk screws (150) and console (145) from structure assy.
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(t) (u) (v) (w) (x) (y) (z) (za) (zb) (zc) (zd) (ze) (zf) (zg) (zh) (zi) (zj) (zk)
Remove countersunk screws (160) and extrusion (155) from structure assy. Remove countersunk screws (235) and extrusions (165, 170, 175, 180, 185) from structure assy. Remove pan-head screws (200, 220) and single revolving catches (190, 195, 210, 215) from structure assy. Remove single revolving catches (205, 225) from structure assy. Remove countersunk screws (245), washers (250), hexagonal nuts (255) and upper attachment brackets (240) from structure assy. Remove countersunk screws (160), guides (260) and extrusion (265) from structure assy. Remove countersunk screws (300), pan-head screws (305), washers (310) and lower attachment brackets (295, 370) from structure assy. Remove countersunk screws (340) and bumpers (335) from structure assy. Remove countersunk screws (360), spacers (355), shims (350) and bumpers (345) from structure assy. Remove countersunk screws (160) and cover (365) from structure assy. Remove countersunk screws (160), bumpers (390) and shim (395) from structure assy. Remove countersunk screws (160) and guides (475) from structure assy. Remove cover caps (480) from structure assy. Remove countersunk screws (235, 550) and strikes (485) from structure assy. Remove bonding clip (-540) from structure assy. Remove extrusions (545) from structure assy. Remove brackets (575, -595) and extrusions (580, -600) from structure assy. Pull off work counter top (65), velcro (85), guides (280, 285, -290, 400, 405, 565), sliding strips (270, 430, 440, 450, 455, 490, 515, 520, 555, -560, 585, 605, 610), shims (435, -445, 460, 510, -570, 590, 615) from structure assy in case of damage only.
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(6)
Galley unit G6 Structure assy (a) Removal of refrigerators (refer IPC, fig 3E) 1 Remove pan-head screws (85), washers (90) and refrigerators from compartments 608, 609 and 610. (b) Removal of beverage makers 1 Remove beverage makers from compartments 612, 613 and 614. (c) Removal of hot jugs 1 Remove hot jugs from compartments 615, 616 and 617. (d) Removal of insulated folding door assemblies (40, 70) (refer IPC, fig 4E) 1 Remove countersunk screws (45, 75), washers (50, 80) and insulated folding door assemblies (40, 70) from structure assy (-1). (e) Removal of insulated door assemblies (55, 85) 1 Remove countersunk screws (60, 90), washers (65, 95) and insulated door assemblies (55, 85) from structure assy. (f) Removal of door assemblies (100, 115) 1 Remove countersunk screws (105, 120), washers (110, 125) and door assemblies (100, 115) from structure assy. (g) (h) (i) (j) (k) Remove single revolving catches (130, 135, 140, 145, 150) from structure assy. Remove pan-head screws (160) and single revolving catches (155) from structure assy. Remove cover (-185) from structure assy. Pull off guides (-165, 170) from structure assy in case of damage only. Separation of lower part assy (5), upper part assy (10) and rear part assy (25) 1 Disconnect electrical system (10, fig 3E), water installation assy (15, fig 4E), ventilation system (20, fig 3E) and cooling system (25. fig 3E) between structure parts and from airplane supply systems. 2 Remove decorative materials (35, fig 3E)
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3 Remove joint covers (395, fig6B; 405, fig 6B) from structure assy. 4 Remove countersunk screws (30, 35), pan-head screws (175), washers (180) and rear part assy (25) from lower part assy (5) and from upper part assy (10). 5 Remove countersunk screws (20, fig 1) and AFT partition (55, fig 1) from lower part assy (5) and from and from upper part assy (10). 6 Remove allen screws (15, 20) and upper part assy (10) from lower part assy (5). (7) Galley unit G7 Structure assy (a) Removal of bun warmers (refer IPC, fig 3F) 1 Remove countersunk screws (85) and bun warmers from compartments 701, 702 and 703. (b) Removal of steam ovens 1 Remove pan-head screws (90) and steam ovens from compartments 710, 711, 712, 713, 714 and 715. (c) Removal of insulated folding door assemblies (45, 75) (refer IPC, fig 4F) 1 Remove countersunk screws (50, 80), washers (55, 85) and insulated folding door assemblies (45, 75) from structure assy (-1). (d) Removal insulated door assemblies (60, 90) 1 Remove countersunk screws (65, 95), washers (70, 100) and insulated door assemblies (60, 90) from structure assy. (e) Removal of door assemblies (105, 120) 1 Remove countersunk screws (110, 125), washers (115, 130) and door assemblies (105, 120) from structure assy. (f) Removal of sliding coat rod assy (160) 1 Remove countersunk screws (165, 170), spacers (175) and sliding coat rod assy (160) from structure assy. (g) (h) Remove single revolving catches (135, 140, 145) from structure assy. Remove pan-head screws (155) and single revolving catches (150) from structure assy.
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(i)
Separation of lower part assy (5), upper part assy (10) and rear part assy (25) 1 Disconnect electrical system (10, fig 3F), water installation assy (15, fig 3F), ventilation system (20, fig 3F) and cooling system (25, fig 3F) between structure parts and from airplane supply systems. 2 Remove decorative materials (35, fig 3F). 3 Remove joint covers (420, fig 6C, 430, fig 6C) from structure assy. 4 Remove countersunk screws (30, 35), pan-head screws (180), washers (40, 185) and rear part assy (25) from upper part assy (10) and lower part assy (5). 5 Remove countersunk screws (70, fig 1) and AFT partition assy (55, fig 1) from lower part assy (5) and from upper part assy (10). 6 Remove allen screws (15, 20) and upper part assy (10) from lower part assy (5).
(8)
Bar unit G4A Structure assy (a) Remove pan-head screw (70), washer (75), pip-pin (60) with securing rope (65) and tie rod (55) from upper attachment bracket (10, fig 6D) (refer IPC, fig 4G). Remove countersunk screws (50) and bracket (45) from structure assy. Remove countersunk screws (175), extrusions (-100, 105, 110, -115, -120, 125, -130, 135), sealing profiles (85, 90, 95) and shims (140, 145, -150, -155, 160, 165, -170) from structure assy. Remove countersunk screws (190) and covers (180, 185) from structure assy. Remove countersunk screws (195) and coat rods (80) from structure assy. Separation of lower part assy (5), upper part assy (10) and rear part assy (30) 1 Disconnect electrical system (10, fig 3G) and water installation assy (15, fig 3G) between structure parts and from airplane supply systems. 2 Remove decorative materials (25). 3 Remove joint covers (80, fig 6D) from structure assy. 4 Remove countersunk screws (35), allen screws (40) and rear part assy (30) from upper part assy (10) and lower part assy (5).
(b) (c)
(d) (e) (f)
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5 Remove allen screws (20, 25), special nuts (15) and upper part assy (10) from lower part assy (5). (9) RH closet unit Structure assy (a) (b) (c) Disconnect electrical system (-10) from airplane supply system (refer IPC, fig 3H). Remove decorative materials (20). Removal of folding bottom assy (5) (refer IPC, fig 4H) 1 Remove pan-head screws (10) and folding bottom assy (5) from structure assy (-1). (d) Removal of roller blind assy (15) 1 Open roller blind (5, fig 16). 2 Remove pan-head screws (155), washers (160) and bumper (150) from roller blind (5, fig 16). 3 Remove plate (170) from structure assy. NOTE: To prevent damage, roll up roller blind with decorative material on outside. 4 Pull out roller blind (5, fig 16) from extrusions (90, -95, -100, 135, 140, 145). 5 Remove countersunk screws (20) and extrusions (90, -95, -100, 135, 140, 145) from structure assy. (e) (f) (g) (h) (i) (j) (k) Remove countersunk screws (30) and coat rod (25) from structure assy. Remove hexagonal screws (40), hexagonal nuts (50), washers (45) and upper attachment brackets (35) from structure assy. Remove countersunk screws (30) and covers (55) from structure assy. Remove countersunk screws (65) and lamp casing (60) from structure assy. Remove countersunk screws (75) and covers (70) from structure assy. Remove countersunk screws (85) and access cover (85) from structure assy. Remove extrusions (90, -95, -100, 135, 140, 145) from structure assy.
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(l) (m) (n) (o) (10)
Remove countersunk screws (110) and lower attachment brackets (105) from structure assy. Remove countersunk screws (120) and strike (115) from structure assy. Remove countersunk screws (120, 165), strike (115), retainer (125) and bumper (130) from structure assy. Remove pan-head screws (155), washers (160) and bumpers (150) from structure assy.
RH Coat closet door 2 Structure assy (a) (b) (c) Disconnect electrical system (-10) from airplane supply system (refer IPC, fig 3J). Remove decorative materials (20). Removal of door assy (5) (refer IPC, fig 4J) 1 Remove countersunk screws (10) and door assy (5) from structure assy. (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) Remove pan-head screw (65), washer (70), pip-pin (55) with securing rope (60) and tie rod (50) from upper attachment bracket (105). Remove countersunk screws (20) and coat rod (15) from structure assy. Remove countersunk screws (30) and extrusion (25) from structure assy. Remove countersunk screws (45) and covers (-35, 40) from structure assy. Remove countersunk screws (80) and fitting (75) from structure assy. Remove pan-head screws (95), washers (100) and extrusion (90) from structure assy. Remove hexagonal screws (110), washers (115) and upper attachment bracket (105) from structure assy. Remove access cover (120) from structure assy. Remove countersunk screws (130) and strike (125) from structure assy. Pull off Teflon (85) from structure assy in case of damage only.
(11)
AFT Partition assy (a) Disconnect electrical system (10) from airplane supply system (refer IPC, fig 3K).
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(b)
Removal of decorative materials (-15) 1 Pull off decorative materials (20) in case of damage onlyq
(c)
Removal of access flap assy (5) 1 Loosen fasteners (10) and remove access flap assy (5). 2 Remove fasteners (10), rivets (35), cover (45), perforated plate (15), hinge (20), bumpers (25), spring (30) and from access flap assy.
(d)
Removal of retainer assemblies (-50, -70, -90) 1 Remove pan-head screws (145), washers (130) and retainer assemblies (-50, -70, -90) from structure assy. 2 Remove countersunk screws (65, 85, 105) and extrusions (60, 80, 100) from retainers. 3 Pull off sealing profiles (110) from retainers (55, 75, 95) in case of damage only.
(e) (f) (g) (h) (i) (j) C.
Remove countersunk screws (150) and air grid (45) from structure assy. Remove pan-head screws (125), washers (130) and extrusion (120, 135) from structure assy. Remove pan-head screws (145), washers (130) and air boxes (140) from structure assy. Remove pan-head screws (145), washers (130), supports (155) and clamps (165, 170, 175) from structure assy. Remove clamps (175), sleves (180), hoses (185), insulating hoses (190) and T-fitting (160) from structure assy. Remove countersunk screws (115) and cover (195) from structure assy.
Lower Part Assemblies units G1, G4, G6, G7, G4A (1) Lower part assy - Unit G1 (refer IPC, fig 5) (a) Removal of folding door assemblies (5) 1 Remove pan-head screws (10) and folding door assy (5) from lower part assy (-1).
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(b)
Removal of door assemblies (15, 25, 45, 55) 1 Remove pan-head screws (20, 30, 40, 50, 60) and door assemblies (15, 25, 35, 45, 55) from lower part assy.
(c)
Removal of guide assemblies (75, 85, 105 1 Remove pan-head screws (135), washers (140), guide assemblies (75, 85, 105) from lower part assy. 2 Pull off sliding strips (80, 90, 110) from guide assemblies (75, 85, 105) in case of damage only.
(d)
Removal of guide assemblies (65, 95, 115, 125) 1 Remove pan-head screws (135), washers (140), guide assemblies 65, 95, 115, 125), extrusions (235) and sealing profiles (230) from lower part assy. 2 Pull off sliding strips (70, 100, 120, 130) from guide assemblies (65, 95, 115, 125) in case of damage only.
(e)
Removal of cover assy (145) 1 Remove pan-head rivets (175) and cover assy (145) from lower part assy. 2 Remove pan-head rivets (160) and extrusions (150, 155) from cover assy (145). 3 Remove countersunk screws (170) and strike (165) from cover assy (145).
(f)
Removal of cover assy (180) 1 Remove countersunk screws (205) and cover assy (180) from lower part assy. 2 Drill out countersunk rivets (200) and remove sealing profile (185) and plates (190, 195) from cover assy (180). 3 Pull off sealing profiles (185) from cover assy (180) in case of damage only.
(g)
Removal of cover assy (210) 1 Remove countersunk screws (205, 220) and cover assy (210) from lower part assy. 2 Remove plate (215) from cover assy (210).
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(h)
Removal of cover assemblies (300, 365, 385, 400) 1 Remove countersunk screws (320), pan-head screws (315), washers (140) and cover assemblies (300, 365, 385, 400) from lower part assy. 2 Remove plate (305, 370, 390, 410) and sealing profile (310, 375, 390, 405) from cover assemblies (300, 365, 385, 400.
(i) (j) (k) (l) (m) (n) (o) (p) (2)
Remove countersunk screws (205) and access cover (225) from lower part assy. Remove pan-head screws (240), washers (140), extrusions (235) and sealing profile (230) from lower part assy. Remove pan-head screws (260), washers (140), extrusions (250, 255) and sealing profile (245) from lower part assy. Remove countersunk screws (270) and lower attachment bracket (265) from lower part assy. Remove countersunk screws (295), pan-head screws (285), washers (290) and lower attachment brackets (280) from lower part assy. Remove countersunk screws (295), pan-head screws (360), washers (290) and lower attachment bracket (355, 380) from lower part assy. Remove countersunk screws (420) and access cover (415) from lower part assy. Pull off bumpers (325, 335, 350) and shims (330, 340) from lower part assy in case of damage only.
Lower part assy unit G4 (refer IPC, fig 5A) (a) Removal of insulated door assemblies (5) 1 Remove pan-head screws (10) and insulated door assy (5) from lower part assy (-1). (b) Removal of insulated folding door assy (15) 1 Remove pan-head screws (20) and insulated folding door assy (15) from lower part assy. (c) Removal of door assy (25) 1 Remove pan-head screws (30) and door assy (25) from lower part assy. (d) Removal of waste container (35) 1 Open door and remove waste container assy (35) from compartment 412.
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(e) (f)
Remove countersunk screws (45) and waste chute (40) from lower part assy. Removal of guide assemblies (50, 60) 1 Remove pan-head screws (85) and guide assemblies (50, 60) from lower part assy. 2 Pull off sliding strips (55, 65) from guide assemblies (50, 60) in case of damage only.
(g)
Removal of extrusion assy (105) 1 Remove pan-head screws (135) and extrusion assy (105) from lower part assy. 2 Remove pan-head screws (120), hexagonal nuts (130), washers (125), extrusion (115) and sealing profile (110) from extrusion assy (105).
(h)
Removal of access cover assemblies (145, 160) 1 Loosen fasteners (150, 165) and remove access cover assemblies (145, 160). 2 Remove fasteners (150, 165) and washers (155, 170) from access cover assemblies (145, 160).
(i) (j) (k) (l) (m) (n) (o) (p) (q)
Remove pan-head screws (85), extrusions (80) and sealing profiles (70) from lower part assy. Remove pan-head screws (85), bumpers (95) and shims (100) from lower part assy. Drill out countersunk rivets (230) and remove countersunk screws (235), extrusion (225), retainer (220) and sealing profile (75) from lower part assy. Remove countersunk screws (245) and lower attachment brackets (140) from lower part assy. Remove countersunk screws (250), pan-head screws (255), washers (260) and lower attachment brackets (190) from lower part assy. Remove pan-head screws (85) and extrusions (185, 200) from lower part assy. Remove air grid (195) from lower part assy. Remove countersunk screws (215) and strike (210) from lower part assy. Pull off bumpers (95, 265), shims (100), guides (180) and sliding strips (205, 240) from lower part assy in case of damage only.
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(3)
Lower part assy unit G6 (refer IPC, fig 5B) (a) Removal of casing assy (5) 1 Remove pan-head screws (15), washers (20), supports (10) shims (25) and casing assy (5) from lower part assy (-1). (b) Removal of box assy (30) 1 Remove pan-head screws (40), washers (45) supports (35) shims (50) and box assy (30) from lower part assy. (c) Removal of guide assy (260) 1 Remove countersunk screws (170), washers (100) and guide assy (260) from lower part assy. 2 Pull off sliding strip (-265) from guide assy (260) in case of damage only. (d) Removal of guide assemblies (305, -315, 345, 355, 385, 395) 1 Remove pan-head screws (95, 210), washers (100) and guide assemblies (305, -315, 345, 355, 385, 395) from lower part assy. 2 Pull off sliding strips (310, -320, 350, 360, 390, 400) from guide assemblies (305, -315, 345, 355, 385, 395) in case of damage only. (e) Removal of cover assemblies (75, 235) 1 Remove pan-head screws (90, 95), washers (100) and cover assemblies (75, 235). 2 Remove plates (-80, -245) from cover assemblies (75, 235). 3 Pull off sealing profiles (-85, -240) from cover assemblies (75, 235) in case of damage only. (f) Removal of cover assy (150) 1 Remove countersunk screws (170), pan-head screws (90), washers (100) and cover assy (150) from lower part assy. 2 Remove plates (-155) from cover assy (150). 3 Pull off sliding strips (-160), sealing profiles (-165) from cover assy (150) in case of damage only.
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(g)
Removal of cover assy (330) 1 Remove countersunk screws (300), pan-head screws (95), washers (100) and cover assy (330) from lower part assy. 2 Pull off sliding strip (-335) from cover assy (330) in case of damage only.
(h)
Removal of cover assy (365) 1 Remove countersunk screws (170), pan-head screws (90), washers (100) and cover assy (365) from lower part assy. 2 Remove plate (-370) and from cover assy (365). 3 Pull off sliding strip (-375) and sealing profile (-380) from cover assy (365) in case of damage only.
(i) (j) (k) (l) (m) (n) (o) (p) (q) (4)
Remove pan-head screws (90, 95), washers (100) and covers (280, 285, 340) from lower part assy. Remove countersunk screws (60), pan-head screws (65), washers (70) and lower attachment brackets (55, 145, 230, 275, 325) from lower part assy. Remove pan-head screws (95), washers (100), extrusions (110) and sealing profile (115) from lower part assy. Remove pan-head screws (210), washers (100), extrusions (190, 195) and sealing profile (200) from lower part assy. Remove countersunk screws (300) and covers (290, 295) from lower part assy. Remove countersunk screws (60) and extrusions (215, 220) from lower part assy. Remove access cover (120) from lower part assy. Remove extrusion (405) and from lower part assy. Pull off bumpers (125, 130, 135), sealing profile (410), guides (180, 185, 270) and shims (140, 220) from lower part assy in case of damage only.
Lower part assy unit G7 (refer IPC, fig 5C) (a) Removal of casing assemblies (5, 30) 1 Remove pan-head screws (15, 40), washers (20, 45), supports (10, 35) shims (25, 50) and casing assemblies (5, 30) from lower part assy.
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(b)
Removal of guide assemblies (270, 375, 385, 430, 440) 1 Remove pan-head screws (95, 225) washers (100), extrusions (260, 340, 450), sealing profiles (265, 455, 345) and cover assemblies (270, 375, 385, 430, 440) from lower part assy. 2 Pull off sliding strips (275, 325, -335, 380, 390, 435, -445) from cover assemblies (270, 375, 385, 430, 440) in case of damage only.
(c)
Removal of cover assemblies (75, 245, 300) 1 Remove countersunk screws (180), pan-head screws (90, 95), washers (100) and cover assemblies (75, 245, 300) from lower part assy. 2 Remove plates (-80, -250, -305) from cover assemblies (75, 245, 300). 3 Pull off sliding strip (-310) and sealing profiles (-85, -255, -315) from cover assemblies (300) in case of damage only.
(d)
Removal of cover assemblies (260, 400) 1 Remove countersunk screws (180), pan-head screws (90), washers (100) and cover assemblies (260, 400). 2 Remove plates (-165, -405) from cover assemblies (260, 400). 3 Pull off sliding strips (-170, -410) and sealing profiles (-175, 415) from cover assemblies (260, 400) in case of damage only.
(e)
Removal of cover assemblies (360, 420) 1 Remove countersunk screws (395), pan-head screws (90, 95), washers (100) and cover assemblies (360, 420) from lower part assy. 2 Pull off sliding strips (365, 420) from cover assemblies (360, 420) in case of damage only.
(f)
Remove countersunk screws (60), pan-head screws (65), washers (70) and lower attachment brackets (55, 155, 240, 290, 355) from lower part assy. Remove pan-head screws (95), washers (100) extrusions (110) and sealing pro files (115) from lower part assy. Remove access cover (120) from lower part assy.
(h) (i)
(j) Remove countersunk screws (150) and bracket (145) from lower part assy.
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(k) (l) (m) (n) (o) (5)
Remove pan-head screws (225), washers (100), extrusions (210, 205) and sealing profiles (215) from lower part assy. Remove countersunk screws (60) and extrusions (230, 235) from lower part assy. Remove pan-head screws (90, 95), washers (100) and covers (295, 370) from lower part assy. Remove plate (350) from lower part assy. Pull off bumpers (125, 130, 135), shims (140, 200), guides (190, 195) and sliding strip (220) from lower part assy in case of damage only.
Lower part assy unit G4A (refer IPC, fig 5D) (a) Removal of door assemblies (5, 15, 25, 35) 1 Remove countersunk screws (10, 20, 30, 40) and door assemblies (5, 15, 25, 35) from lower part assy (-1). (b) Removal of waste container (45) 1 Open door and remove waste container assy (45) from compartment 4A07. (c) Removal of guide assemblies (50, 65) 1 Remove pan-head screws (60) and guide assemblies (50, 65) from lower part assy. 2 Pull off sliding strips (55, 70) from guide assemblies (50, 65) in case of damage only. (d) (e) Remove countersunk screws (80) and lower attachment brackets (75) from lower part assy. Remove countersunk screws (90) and brackets (85, 95) from lower part assy.
(f) Remove countersunk screws (120) and strikes (115) from lower part assy. (g) Removal of revolving catch assy (135) 1 Remove slotted pin (35, fig 21A), knob (30, fig 21A) and washer (15, fig 21A) from axle (10, fig 21A). 2 Remove countersunk screws (20, fig 21A) and cover (25, fig 21A) from sup port (5, fig 21A).
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3 Remove setscrew (60, fig 21A), ball catch (40, fig 21A), axle (10, fid 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) from support (5, fig 21A). 4 Remove pan-head screws (140) and support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) from upper part assy. 5 Remove bushings (55, fig 21A; 65, fig 21A) from support (5, fig 21A) (h) (i) (j) (k) (l) (m) (m) Remove pan-head screws (155), single revolving catches (145, 150) and double revolving catches (160) from lower part assy. Remove cover (165) from lower part assy. Remove filling strip (195) from protecting strip (190). Remove pan-head screws (205), end parts (200) and protecting strip (190) from lower part assy. Loosen fasteners (230), drill out countersunk rivets (235) and remove cover (225) from lower part assy. Remove fasteners (230) from cover (225). Pull off bumpers (180, 210), sliding strips (105, 125, 170, 220, 240) and shims (110, 130, 175, 185, 215) from lower part assy in case of damage only.
D.
Upper Part Assemblies Unit G1, G2, G3, G4 And G5 (1) Upper part assy unit G1 (refer IPC, fig 6) (a) Removal of door assy (5) 1 Remove pan-head screws (10) and door assy (5) from upper part assy (-1). (b) Removal of sliding work table assemblies (15, 25) NOTE: Prior to release the pan of sliding work table, make sure, that the attachment screws have been entirely pulled downwards and a minimum space 8,0 mm (0.32) between the upper surface of the retainer and the surface of the shell is granted. These can be checked e.g. with fingertip. 1 Loosen retainers (20, 30) and sliding work table assemblies (15, 25) from upper part assy. 2 Remove retainers (20, 30) from sliding work table assemblies (15, 20).
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(c)
Removal of hot cup retainer assy (35) 1 Remove countersunk screws (40) and hot cup retainer assy (35) from upper part assy.
(d)
Removal of disengaging installation devise (45) 1 Remove countersunk screws (65), pan-head screws (55), bushings (60), threaded bushings (50) and disengaging installation assy (45) from upper part assy.
(e) (f)
Remove countersunk screws (480) and perforated cover (100) from sink assy (85). Removal of sink assy (85). 1 Remove sink assy (85) from upper part assy. 2 Remove countersunk screws (95) and sieve (90) from sink assy (85).
(g)
Removal of support assemblies (125, 135, 145, -155, 165) 1 Remove pan-head screws (120) and support assemblies (125, 135, 145, -155, 165) from upper part assy. 2 Pull off sliding strips (130, 140, 150, -160, 170) from support assemblies (125, 135, 145, -155, 165) in case of damage only.
(h)
Removal of cover assemblies (175, -355) 1 Remove cover assemblies (175, -355) from upper part assy. 2 Remove closing cap (185) from cover assy (175). 3 Pull off velcros (180, 190, -360, -365) from cover assemblies (175, -355) in case of damage only.
(i)
Removal of outlet cover assy (460) 1 Remove countersunk screws (480) and outlet cover assy (460) from upper part assy. 2 Remove pan-head screws (470), washers (475) and cover (465) from outlet cover assy (460).
(j)
Removal of plug support assemblies (195, 225) 1 Remove pan-head screws (120) and plug support assemblies (195, 225) from upper part assy.
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2 Drill out countersunk rivets (210, 240) and remove countersunk screws (205, 235) and spacers (200, 230) from plug support assemblies. 3 Remove pan-head screws (220, 250) and alignment bushings (215, 245) from plug support assemblies (195, 225). (k) Removal of air screen box assy (415) 1 Remove pan-head screws (120) and air screen box assy (415) from upper part assy. 2 Removal of air screen assy (420) a Loosen fastener (435) and remove air screen assy (420) from air screen box assy (415). b Remove fastener (435) and washer (440) from air screen assy (420). c Remove retainer (430) and filter pad (425) from air screen assy (420). 3 Remove pan-head screws (450), hexagonal nuts (455) and tube (445) from air screen box assy (415). (l) (m) Remove pan-head screws (120)and exhaust hood (500) from upper part assy. Removal of air screen assy (505) 1 Loosen fasteners (520) and remove air screen assy (505) from upper part assy. 2 Remove fasteners (520) from air screen assy (505). 3 Remove retainer (510) and filter pad (515) from air screen assy. (n) Removal of drip pan assy (655) 1 Remove drip pan assy (655) from upper part assy. 2 Remove countersunk screws (665) and sieve (660) from drip pan assy (655). (o) Removal of revolving catch assy (580) 1 Remove slotted pin (35, fig 21), knob (60, fig 21) and distance bushing (20, fig 21) from axle (10, fig 21). 2 Remove setscrew (45, fig 21), ball catch (30, fig 21), axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) from support (5, fig 21).
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3 Remove pan-head screws (585), support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) from upper part assy. 4 Remove bushing (40, fig 21) and distance bushing (25, fig 21)from support (5, fig 21). (p) Removal of revolving catch assy (610) 1 Remove slotted pin (35, fig 21A), knob (30, fig 21A) and washer (15, fig 21A) from axle (10, fig 21A). 2 Remove countersunk screws (20, fig 21A) and cover (25, fig 21A) from sup port (5, fig 21A). 3 Remove setscrew (60, fig 21A), ball catch (40, fig 21A), axle (10, fid 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) from support (5, fig 21A). 4 Remove countersunk screws (615) and support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) from upper part assy. 5 Remove bushings (55, fig 21A; 65, fig 21A) from support (5, fig 21A) (q) (r) (s) (t) (u) (v) (w) (x) (y) (z) (za) Remove countersunk screws (115), pan-head screws (120) and covers (105, 110) from upper part assy. Remove pan-head screws (260) and extrusion (255) from upper part assy. Remove pan-head screws (65), countersunk screws (115) and extrusion (265) from upper part assy. Remove access cover (-270) from upper part assy. Remove countersunk screws (280) and extrusion (275) from upper part assy. Remove pan-head screws (120) and air grid (285) from upper part assy. Remove countersunk screws (325) and extrusions (290, 295, 300, 305, 310) from upper part assy. Remove countersunk screws (280), extrusions (315, 320), spacer (340) and plate (345) from upper part assy. Remove pan-head screws (120) and air grids (330, 335) from upper part assy. Remove extrusion (350) from upper part assy. Remove pan-head screws (120) and extrusions (-370, 375, 380) from upper part assy.
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(zb) (zc) (zd) (ze) (zf) (zg) (zh) (zi) (zj) (zk) (zl) (zm) (2)
Remove countersunk screws (390) and sieve (395) from upper part assy. Remove countersunk screws (410), ball catch (395) and plates (405, 400) from upper part assy. Remove hexagonal screws (490), washers (495) and upper attachment bracket (485) from upper part assy. Remove countersunk screws (540), bumpers (530) and shims (535) from upper part assy. Remove pan-head screws (120) and support (545) from upper part assy. Remove countersunk screws (565), guide (555) and spacers (560) from upper part assy. Remove countersunk screws (565) and plate (590) from upper part assy. Remove countersunk screws (115) and extrusion (595) from upper part assy. Remove countersunk screws (630), bumper (620) and shim (625) from upper part assy. Remove countersunk screws (640), hexagonal nuts (650), washers (645) and upper attachment bracket (635) from upper part assy. Remove countersunk screws (280) and shell (675) from upper part assy. Pull off work counter tops (70, 75, 80), guides (550, 670), sliding strips (600) and shims (605) from upper part assy in case of damage only.
Upper part assy unit G4 (refer IPC, fig 6A) (a) Removal of door assy (5) 1 Remove countersunk screws (10) and door assy (5) from upper part assy (-1). (b) Removal of sliding work table (15) 1 Loosen retainer (20) and sliding work table (15) from upper part assy. 2 Remove retainer (20) from upper part assy. (c) Removal of disengaging installation assy (25) 1 Remove countersunk screws (45), pan-head screws (35), bushings (40), threaded bushings (30) and disengaging installation assy (25) from upper part assy.
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(d)
Removal of upper attachment assy (50) 1 Remove hexagonal screws (55, 70), hexagonal nuts (65, 80), washers (60, 75) and upper attachment assy (50) from upper attachment brackets (225, 230).
(e)
Removal of work light assy (85) 1 Remove pan-head screws (35) and work light assy (85) from upper part assy. 2 Remove pan-head screws (95) and work light (90) from work light assy (85).
(f)
Removal of plug support assy (100) 1 Remove pan-head screws (135) and plug support assy (100) from upper part assy. 2 Remove pan-head screws (110), washers (115) and alignment bushings (105) from plug support assy (100). 3 Remove countersunk screws (125) and spacer (120) from plug support assy (100).
(g)
Removal of revolving catch assy (365) 1 Remove slotted pin (35, fig 21), knob (60, fig 21) and distance bushing (20, fig 21) from axle (10, fig 21). 2 Remove setscrew (45, fig 21), ball catch (30, fig 21), axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) from support (5, fig 21). 3 Remove pan-head screws (370), support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) from upper part assy. 4 Remove bushing (40, fig 21) and distance bushing (25, fig 21)from support (5, fig 21).
(h)
Removal of waste flap assy (385) 1 Remove countersunk screws (215) and waste flap assy (385) from upper part assy. 2 Drill out countersunk rivets (-395) and remove hinge (-390) from waste flap assy (385).
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3 Remove countersunk screws (-405) and knob (-400) from waste flap assy (385). (i) Removal of drip pan assemblies (465, 480) 1 Remove drip pan assemblies (465, 480) from upper part assy. 2 Remove countersunk screws (475, 490) and sieves (470, 485) from drip pan assemblies (465, 480). (j) Removal of plug support assy (500) 1 Remove pan-head screws (135), washers (285) and plug support assy (500) from upper part assy. 2 Remove pan-head screws (510) and cover (505) from plug support assy (500). (k) Removal of revolving catch assy (545) 1 Remove slotted pin (35, fig 21A), knob (30, fig 21A) and washer (15, fig 21A) from axle (10, fig 21A). 2 Remove countersunk screws (20, fig 21A) and cover (25, fig 21A) from sup port (5, fig 21A). 3 Remove setscrew (60, fig 21A), ball catch (40, fig 21A), axle (10, fid 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) from support (5, fig 21A). 4 Remove countersunk screws (550) and support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) from upper part assy. 5 Remove bushings (55, fig 21A; 65, fig 21A) from support (5, fig 21A) (l) Removal of air screen box assy (575) 1 Remove pan-head screws (625) and air screen box assy (575) from upper part assy. 2 Removal of air screen assy (580) a Loosen fastener (-595) and remove air screen assy (580) from air screen box assy (575). b Remove fastener (-595) from air screen assy (580). c Remove retainer (-590) and filter pad (-585) from air screen assy (580).
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3 Remove pan-head screws (-610), hexagonal nuts (-620), washers (-615), air grid (-600) and tube (-605) from air screen box assy (575). (m) Removal of sink complete assy (670) 1 Remove perforated cover (690) from sink assy (675). 2 Remove countersunk screws (-710), extrusion (-705), and work counter top (695) from sink complete assy (670). 3 Removal of sink assy (675) a Remove sink assy (675) from sink complete assy (670). b Remove countersunk screws (-685) and sieve (-680) from sink assy (675). 4 Pull off shim (-700) from sink complete assy (670) in case of damage only. (n) (o) (p) (q) (r) (s) (t) (u) (v) (w) (x) Remove pan-head screws (135) and cover (130) from upper part assy. Remove air grids (140, 145, -150, 155, -160, -165, 170) from upper part assy. Remove countersunk screws (180), pan-head screws (135) and cover (175) from upper part assy. Remove countersunk screws (90, 95) and extrusion (185) from upper part assy. Remove countersunk screws (205) and spacers (200) from upper part assy. Remove countersunk screws (215, 220) and extrusions (210) from upper part assy. Remove hexagonal screws (235), washers (240) and upper attachment brackets (225, 230) from upper part assy. Remove pan-head screws (250), washers (255) and extrusion (245) from upper part assy. Remove countersunk screws (195, 275), extrusion (260), spacers (265) and sliding strips (270) from upper part assy. Remove pan-head screws (135), washers (285) and extrusion (280) from upper part assy. Remove countersunk screws (325) and roller blind latch (320, 350) from upper part assy.
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(y) (z) (za) (zb) (zc) (zd) (ze) (zf) (zg) (zh) (zi) (zj) (zk) (zl) (zm) (zn) (zo) (zp)
Remove pan-head screws (135) and extrusion (330) from upper part assy. Remove countersunk screws (340) and extrusion (335) from upper part assy. Remove countersunk screws (325) and roller blind latch (350) from upper part assy. Remove countersunk screws (340) and extrusion (355) from upper part assy. Remove countersunk screws (275) and guides (375) from upper part assy. Remove countersunk screws (45) and waste cover (410) from upper part assy. Remove countersunk screws (420), extrusion (415) and shims (455, 460) from upper part assy. Remove countersunk screws (435) and extrusions (425, 430) from upper part assy. Remove extrusion (440, -570, 650, 660) from upper part assy. Remove pan-head screws (45), extrusions (525, 530) and sliding strips (535, 540) from upper part assy. Remove countersunk screws (45) and bumpers (355) from upper part assy. Remove countersunk screws (340) and strike (640) from upper part assy. Remove countersunk screws (45) and access cover (645) from upper part assy. Remove bonding clip (-495) from upper part assy. Remove extrusions (300, -345) from upper part assy. Remove pan-head screws (-720), washers (285) and cover (-715) from upper part assy. Remove pan-head screws (135) and cover (725) from upper part assy. Pull off extrusions (300, -345), sliding strips (305, 310, 315, 360, 445, 560, 565, 630, 635, 655, 665) and shims (450, -515, -520) from upper part assy in case of damage only.
(3)
Upper part assy unit G6 (refer IPC, fig 6B) (a) Removal of insulated door assy (5) 1 Remove countersunk screws (10), washers (15) and insulated door assy (5) from upper part assy.
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(b)
Removal of door assy (5) 1 Remove countersunk screws (25), washers (30) and door assy (20) from upper part assy.
(c)
Removal of sliding work table assy (35) 1 Loosen retainer (40) and remove sliding work table (35) from upper part assy. 2 Remove retainer (40) from sliding work table assy (35)
(m)
Removal of complete sink assy (55) 1 Remove perforated cover (80) from sink assy (55). 2 Remove countersunk screws (195), extrusion (275), and work counter top (50) from complete sink assy (55). 3 Removal of sink assy (60) a Remove sink assy (60) from complete sink assy (55). b Remove pan-head screws (-70) and sieve (-65) from sink assy (60).
(e)
Removal of plug support assemblies (85, 115) 1 Remove pan-head screws (145), washers (150) and plug support assemblies (85, 115) from upper part assy. 2 Remove countersunk screws (95, 125) and spacers (90, 120) from plug sup port assy (85, 115). 3 Remove pan-head screws (105, 135), washers (110, 140) and alignment bushings (100, 130) from plug support assemblies (85, 115).
(f)
Removal of cover assy (175) 1 Loosen fasteners (180) and remove cover assy (175) from upper part assy. 2 Remove fasteners (180) and washers (185) from cover assy (175).
(g)
Removal of revolving catch assy (460) 1 Remove slotted pin (35, fig 21), knob (60, fig 21) and distance bushing (20, fig 21) from axle (10, fig 21).
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2 Remove setscrew (45, fig 21), ball catch (30, fig 21), axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) from support (5, fig 21). 3 Remove pan-head screws (465), support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) from upper part assy. 4 Remove bushing (40, fig 21) and distance bushing (25, fig 21) from support (5, fig 21). (h) Removal of plug support assy (540) 1 Remove pan-head screws (145), washers (150) and plug support assy (540) from upper part assy. 2 Remove pan-head screws (-550) and cover (-545) from plug assy support (540). (i) Removal of drip pan assy (560) 1 Remove drip pan assy (560) from upper part assy. 2 Remove countersunk screws (570) and sieve (565) from drip pan assy (560). (k) Removal of air screen box assy (585) 1 Remove pan-head screws (120) and air screen box assy (585) from upper part assy. 2 Removal of air screen assy (601) a Loosen fastener (-603) and remove air screen assy (601) from air screen box assy (585). b Remove fastener (-603) and washer (-607) from air screen assy (601). c Remove retainer (-603) and filter pad (-605) from air screen assy (601). 3 Remove pan-head screws (-595), hexagonal nuts (-600) and tube (590) from air screen box assy (415). (k) Removal of guide assy (660) 1 Remove pan-head screws (145), washers (150) and guide assy (660) and shims (290) from upper part assy. 2 Pull off sliding strips (-665) from guide assy (660) in case of damage only.
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(l)
Removal of hot cup retainer assy (680) 1 Remove countersunk screws (685) and hot cup retainer assy (680) from upper part assy.
(m) (n) (o) (p) (q) (r) (s) (t) (u) (v) (w)
Remove pan-head screws (145), washers (150) and cover (155) from upper part assy. Remove countersunk screws (170), pan-head screws (145), washers (150) and extrusions (160, 165) from upper part assy. Remove countersunk screws (195) and paper clip (190) from upper part assy. Remove countersunk screws (205) and cup holder (200) from upper part assy. Remove pan-head screws (145), washers (150) and air boxes (210, 215) from upper part assy. Remove pan-head screws (220, 300), washers (150, 225) and extrusion (295) from upper part assy. Remove countersunk screws (205) and extrusions (230) from upper part assy. Remove countersunk screws (195) and extrusions (240, -245, 250, 255, 260, -265, 270, 275, -280) from upper part assy. Remove countersunk screws (170) and extrusion (285) from upper part assy. Remove hexagonal screws (310), washers (315) and upper attachment bracket (325) from upper part assy. Remove countersunk screws (350, 375), hexagonal nuts (355), washers (315, 345), eccentrical bushings (335, 340), shims (330) and upper attachment brackets (325, 370) from upper part assy. Remove countersunk screws (170) and spacer (320) from upper part assy. Remove pan-head screws (145), washers (150) and extrusions (360, 365) from upper part assy. Remove pan-head screws (385), washers (390) and extrusion (380) from upper part assy. Remove access cover (-400), conduit (-415) and covers (-420, -425) from upper part assy. Remove pan-head screws (145, 650), washers (150) and air grids (410) from upper part assy.
(x) (y) (z) (za) (zb)
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(zc) (zd) (ze) (zf) (zg) (zh) (zi) (zj) (zk) (zl) (zm) (zn) (zo) (zp)
Remove countersunk screws (195) and strike (430) from upper part assy. Remove countersunk screws (445), mounting plate (440) and latch (435) from upper part assy. Remove metal sheet (450) from upper part assy. Remove pan-head screws (145), washers (150), extrusion (475) and sealing profile (480) from upper part assy. Remove countersunk screws (205) and access cover (495) from upper part assy. Remove countersunk screws (205) and bracket (525) from upper part assy. Remove countersunk screws (205) and guides (555, 610) from upper part assy. Remove countersunk screws (205), bumpers (580) and shims (575) from upper part assy. Remove pan-head screws (145), washers (150) and air grids (615, 620) from upper part assy. Remove pan-head screws (145), washers (150) and extrusions (-625, 630, -635) from upper part assy. Remove air grid (640) from upper part assy. Remove pan-head screws (145), washers (150) and cover (670) from upper part assy. Remove countersunk screws (195) and shell (690) from upper part assy. Pull off work counter tops (45, 50), guides (455, 485, 500, 655), shims (505, 510, 515, 535) and sliding strips (530) from upper part assy in case of damage only.
(4)
Upper part assy unit G7 (refer IPC, fig 6C) (a) Removal of insulated door assy (5) 1 Remove countersunk screws (10), washers (15) and insulated door assy (5) from upper part assy (-1). (b) Removal of door assy (20) 1 Remove countersunk screws (25), washers (30) and door assy (20) from upper part assy.
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(c)
Removal of sliding work table assy (35) NOTE: Prior to release the pan of sliding work table, make sure, that the attachment screws have been entirely pulled downwards and a minimum space 8,0 mm (0.32) between the upper surface of the retainer and the surface of the shell is granted. These can be checked e.g. with fingertip. 1 Loosen retainer (40) and sliding work table asy (35) from upper part assy. 2 Remove retainer (40) from sliding work table assy (35).
(d)
Removal of plug support assemblies (60, 90, 120) 1 Remove pan-head screws (150), washers (155) and plug support assemblies (60, 90, 120) from upper part assy. 2 Remove countersunk screws (70, 100, -130) and spacers (65, 95, -125) from plug support assemblies (60, 90,120) 2 Remove pan-head screws (80, 110, -140), washers (85, 115, -145) and alignment bushings (75, 105, -135) from plug support assemblies (60, 90, 120).
(e)
Removal of cover assy (160) 1 Remove countersunk screws (245) and cover assy (160) from upper part assy. 2 Remove countersunk screws (170) and shell (165) from cover assy.
(f) (g)
Loosen fasteners (180) and remove washers (185) and cover assy (175) from upper part assy. Removal of cover assy (210) 1 Remove pan-head screws (150), washers (155) and cover assy (210) from upper part assy. 2 Remove pan-head screws (-225), washers (-230), supports (220) and cover (215) from cover assy (210).
(h)
Removal of air duct assy (250) 1 Remove air duct assy (250) from upper part assy. 2 Pull off shim (255) and sealing tape (260) from air duct assy (250) in case of damage only.
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(i) (j)
Remove countersunk screws (55), pan-head screws (150), washers (155), extrusions (300) and exhaust hoods (370) from upper part assy. Removal of air screen assy (375) 1 Loosen fasteners (390) and remove air screen assy (375) from upper part assy. 2 Remove fastener (390) from air screen assy. 3 Remove retainer (380) and filter pad (385) from air screen assy (375).
(k)
Removal of revolving catch assy (535) 1 Remove slotted pin (35, fig 21), knob (60, fig 21) and distance bushing (20, fig 21) from axle (10, fig 21). 2 Remove setscrew (45, fig 21), ball catch (30, fig 21), axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) from support (5, fig 21). 3 Remove pan-head screws (540), support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) from upper part assy. 4 Remove bushing (40, fig 21) and distance bushing (25, fig 21)from support (5, fig 21).
(l)
Removal of guide assy (550) 1 Remove guide assy (550) from upper part assy. 2 Pull off teflon (555) from guide assy (550) in case of damage only
(m)
Removal of guide assemblies (-665, 695, 705) 1 Remove pan-head screws (645), washers (155) and guide assemblies (-665, 695, 705) from upper part assy. 2 Pull off sliding strips (-670, 700, 710) from guide assemblies (-665, 695, 705) in case of damage only.
(n) (o) (p)
Remove countersunk screws (55) and extrusion (50) from upper part assy. Remove countersunk screws (195) and paper clip (190) from upper part assy. Remove pan-head screws (150), washers (155) and extrusion (200) from upper part assy.
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(q) (r) (s) (t) (u) (v) (w)
Remove pan-head screws (150), washers (155) and cover (235) from upper part assy. Remove countersunk screws (245) and sealing profile (240) from upper part assy. Remove countersunk screws (195) and extrusions (265, 270) from upper part assy. Remove pan-head screws (150), washers (155), extrusion (475) and shim (275) from upper part assy. Remove pan-head screws (280, 295), washers (155, 285) and extrusion (290) from upper part assy. Remove hexagonal screws (310), washers (315) and upper attachment bracket (305) from upper part assy. Remove countersunk screws (350, 400), hexagonal nuts (355), washers (315, 345), eccentrical bushings (335, 340) shims (320) and upper attachment brackets (325, 395) from upper part assy. Remove countersunk screws (245) and spacer (320) from upper part assy. Remove pan-head screws (150), washers (155) and extrusions (360, -365) from upper part assy. Remove pan-head screws (410), washers (415) and extrusion (405) from upper part assy. Remove pan-head screws (150), washers (155) and cover (435) from upper part assy. Remove countersunk screws (55) and extrusion (440) from upper part assy. Remove air cover (-425) from upper part assy. Remove conduit (-445) and metal sheet (-450) from structure a Remove countersunk screws (55) and access cover (485) from upper part assy. Remove countersunk screws (55) and guides (500, 505, 510, 515) from upper part assy. Remove pan-head screws (150), washers (155) and covers (520, 525) from upper part assy. Remove pan-head screws (150), washers (155), extrusion (560) and sealing profile (565) from upper part assy.
(x) (y) (z) (za) (zb) (zc) (zd) (zd) (ze) (zf) (zg)
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(zh) (zi) (zj) (zk) (zl) (zm) (zn)
Remove countersunk screws (585), bumpers (575) and shims (580) from upper part assy. Remove pan-head screws (150) and cover (605) from upper part assy. Remove countersunk screws (585) and guide (610) from upper part assy. Remove pan-head screws (150), washers (155) and air grids (615, 620, 625, 630) from upper part assy. Remove pan-head screws (645), washers (155) and air grids (640) from upper part assy. Remove countersunk screws (195) and strikes (680) from upper part assy. Pull off work counter top (45), bumper (-205), guides (455, 460, 490, 650, -675), sliding strips (480, 595, -660, -685) and shims (465, 470, 495, 600) from upper part assy in case of damage only.
(5)
Upper part assy Unit G4A (refer IPC, fig 6D) (a) Removal of ice bucket assy (25) 1 Remove countersunk screws (45) and ice bucket assy (25) from upper part assy. 2 Remove countersunk screws (40), sieve (35) and extrusion (30) from ice bucket assy (25). (b) Remove drip pan assy (95) from upper part assy. 1 Remove countersunk screws (105) and sieve (100) from drip pan assy. (c) (d) (e) (f) (g) (h) (i) Remove work counter top (5) from upper part assy. Remove hexagonal screws (15), washers (20) and upper attachment bracket (10) from upper part assy. Remove cover cap (75) from upper part assy, Remove joint cover (80) from upper part assy. Remove countersunk screws (90) and strikes (85) from upper part assy. Remove countersunk screws (55, 60) and cover (50) from upper part assy. Remove pan-head screws (120), bottle support (110) and bolt (115) from upper part assy.
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(j) E.
Pull off teflon (65, 70) from upper part assy in case of damage only.
Rear Part Assemblies Unit G6, G7 And G4A (1) Rear part assy unit G6 (refer IPC, fig 7) (a) (b) (c) (d) (2) Remove countersunk screws (10), washers (15) and door assy (5) from rear part assy (-1). Remove countersunk screws (55) and strike (50) from rear part assy. Remove countersunk screws (65) and air grid (60) from rear part assy. Pull off sealing profile (70) from rear part assy in case of damage only.
Rear Part Assy Unit G7 (Refer IPC, Fig 7A) (a) (b) (c) (d) Remove countersunk screws (10), washers (15) and door assy (5) from rear part assy (-1). Remove countersunk screws (55) and strikes (50) from rear part assy. Remove countersunk screws (65) and air grid (60) from rear part assy. Pull off sealing profile (70) from rear part assy in case of damage only.
(3)
Rear Part Assy Unit G4A (Refer IPC, Fig 7B) (a) (b) (c) (d) Remove countersunk screws (10) and door assy (5) from rear part assy (-1) Remove countersunk screws (20) and lower attachment brackets (15) from rear part assy. Remove pan-head screws (30), washers (35) and extrusion (25) from rear part assy. Remove joint cover (40) from rear part assy.
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F.
Electrical Systems Unit G1, G2, G3, G4, G5, G6, G7, G4A, RH Closet, Door 2, AFT Partition, G3/G4 And G6/G7 (1) Electrical system - Unit G1 (refer IPC, fig 8) (a) Removal of control panel assy (-5) and control module assy (160) 1 Loosen fasteners (15) and remove control module assy (160). 2 Disconnect control module assy (160) from electrical system. 3 Remove fasteners (15) from control panel (10). 4 Disconnect control panel assy (-5) from control module assy (160). 5 Remove allen screws (25), lock washers (30), washers (35), handles (20) and control panel (10) from control module assy (160). 6 Remove pan-head screws (170), washers (175) and sliding strip (165) from control module assy (160). 7 Pull off adhesive tapes (180) from control module assy (160) in case of damage only. (b) Electrical components 1 Disconnect wires from electrical components. 2 Remove circuit breakers (45, 50, 55, 60, 65, 70), toggle switches (75, 80), indicator lights (85) and bulbs (90) from control panel (10). 3 Remove cover (105, 225), terminal bus (110), terminal board (100) and grommet nut (270) from control module assy (160). 4 Remove lock screw (185), clamps (250, 255, 260, 265), plugs (115, 120, 125, 130, 135) and receptacles (140, 145, 190). 5 Remove indicator light (85), bulb (90), work light (155) and dummy recaptacle (150).
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(c)
Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (340, 375, 410, 440, 480, 510, 565) a Remove hexagonal nuts (370, 405, 435, 475, 505, 535, 575), lock washers (350, 385, 435, 470), washers (365, 400, 425, 465, 495, 525, 585) and wires from hexagonal screws (345, 380, 485, 515), pan-head screw (415), countersunk screw (445) and setscrew (570). b Remove hexagonal nuts (360, 395, 460, 500, 580), washers (355, 390, 420, 450, 455, 495, 525), lock washers (350, 385, 490, 520), hexagonal screws (345, 380, 485) countersunk screw (445), pan-head screw (415) and setscrew (570). 2 Disconnect wires from ground stud assy (540) a Remove hexagonal screw (545), lock washer (550), washers (555, 560) and wires. 3 Remove clamps (-285, -290), washers (295), distance sleeves (-275, -280), conduits (-590, -600, -635, -640, -645), sleeves (-605, -610, -615, -620, -625, -630), soldering sleeve (-595) and wire bundle.
(d)
Remove timer (195), knob (200), fasten tap (205), timer bracket (210), spacer (215), casing (220), sockets (230, 235, 240), cable bracket (245), mounting brackets (300, 305, 310), console (315) and ground stud brackets (320, 325, 330, 335).
(2)
Electrical system - Unit G2 (refer IPC, fig 8A) (a) Removal of control panel assy (-5) and control module assy (185) 1 Loosen fasteners (15) and remove control module assy (185). 2 Remove cover (210) from control module assy (185). 3 Disconnect control module assy (185) from electrical system. 4 Remove fasteners (15) from control panel (10). 5 Disconnect control panel assy (10) from control module assy (185). 6 Remove allen screws (25), lock washers (30), washers (35), handles (20) and control panel (10) from control module assy (185).
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7 Remove pan-head screws (195), washers (200) and sliding strip (190) from control module assy (185). 8 Pull off adhesive tape (-205) from control module assy (185) in case of damage only. (b) Electrical components 1 Disconnect wires from electrical components. 2 Remove circuit breakers (45, 50, 55, 60), toggle switches (65), indicator lights (70, 75, 80) and bulbs (85, 90) from control panel (10). 3 Remove terminal bus (135) and terminal board (125) from control module assy (185). 4 Remove clamps (140, 145, 150), transformer (180) and plugs (95, 100, 105). 5 Remove cover (120), terminal board (115) and dummy receptacle (110). (c) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (215, 250, 285, 315, 345, 400) a Remove hexagonal nuts (245, 280, 310, 340, 370, 410), lock washers (225, 260, 305), washers (240, 275, 300, 330, 360, 420) and wires from hexagonal screws (220, 255, 320, 350), pan-head screw (290) and setscrew (405). b Remove hexagonal nuts (235, 270, 335, 365, 415), washers (230, 265, 295, 330, 360, 420), lock washers (225, 260, 325, 355), hexagonal screws (220, 255, 320, 350), pan-head screw (290) and setscrew (405). 2 Disconnect wires from ground stud assy (375) a Remove hexagonal screw (380), lock washer (385), washers (390, 395) and wires. 3 Remove clamps (-435, -440), washers (-445), terminal lug (-450), distance sleeves (-425, -430), conduits (-455, -460, -465, -470, -475), sleeves (-480, -485, -490) and wire bundle (515). (d) Remove mounting brackets (160), mounting plate (155) and ground stud brackets (170, 175).
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(3)
Electrical system - Unit G3 (refer IPC, fig 8B) (a) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (65, 100) a Remove hexagonal nuts (95, 125), lock washers (75), washers (90, 115) and wires from hexagonal screws (70, 105). b Remove hexagonal nuts (85, 120), washers (80, 115), lock washers (75, 110) and hexagonal screws (70, 105). 2 Disconnect wires from ground stud assy (40) a Remove hexagonal screw (45), lock washer (50), washers (55, 60) and wires. 3 Remove clamps (-20, -25), washers (-30), distance sleeves (-5, -10, -15) and wire bundle. (b) Remove ground stud bracket (35).
(4)
Electrical system - Unit G4 (refer IPC, fig 8C) (a) Removal of control panel assy (-5) and control module assy (220) 1 Loosen fasteners (15) and remove control module assy (220). 2 Remove cover (245) from control module assy (220). 3 Disconnect control module assy (220) from electrical system. 4 Remove fasteners (15) from control panel (10). 5 Disconnect control panel assy (-5) from control module assy (220). 6 Remove allen screws (25), lock washers (30), washers (35), handles (20) and control panel (10) from control module assy (220). 7 Remove pan-head screws (230), washers (235) and sliding strip (225) from control module assy (220). 8 Pull off adhesive tapes (-240) from control module assy (220) in case of damage only.
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(b)
Electrical components 1 Disconnect wires from electrical components. 2 Removal of plug support assy (295) a Remove pan-head screws (135, fig 6A), washers (285, fig 6A) and plug support assy (295). b Remove pan-head screws (-305) and cover (-300) from plug support assy. 3 Remove circuit breakers (45, 50, 55, 60, 65, 70, 75), toggle switches (80, 85), knob (95), rotary switch (90), indicator lights (105, 110, 115), bulbs (120, 125) and from control panel (220). 4 Remove cover (100, 205), terminal bus (210, 215) and terminal board (200) from control module assy (220). 5 Remove clamps (590, 595, 600, 605), grommet nut (610), plugs (135, 140, 145, 150, 155), receptacles (160, 165, 170, 175, 180) and transformer (185). 6 Remove work light (130), cover (195), terminal board (190, 195), terminal block (615, 620) and console (320).
(c)
Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (325, 360, 395, 425, 455, 485, 540) a Remove hexagonal nuts (355, 390, 420, 450, 480, 510, 550), lock washers (335, 370, 415, 445), washers (350, 385, 410, 440, 470, 500, 560) and wires from hexagonal screws (330, 365, 430, 460, 490), pan-head screw (400) and setscrew (545). b Remove hexagonal nuts (345, 380, 475, 505, 555), washers (340, 375, 405, 435, 470, 500, 560), lock washers (335, 370, 465, 495), hexagonal screws (330, 365, 430, 460, 490), pan-head screw (400) and setscrew (545). 2 Disconnect wires from ground stud assy (515, 565) a Remove hexagonal screw (520, 570), lock washer (525, 575), washers (535, 580) and wires.
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3 Remove clamps (-655, -660), washers (-665), rail (-310), end clamp (-315), terminal lug (-625), sockets (-630, -635), distance sleeves (-640, -645, -650), conduits (-670, -675, -680, -685, -690, -695), sleeves (-700, -705,- 710, -715, -720, -725) and wire bundle (585). (d) (5) Remove mounting brackets (250, 260, 265), bracket (255, 285), ground stud brackets (270, 275, 280) and cable bracket (290).
Electrical system - Unit G5 (refer IPC, fig 8D) (a) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (10, 45, 80, 135, 160) a Remove hexagonal nuts (40, 75, 105, 145), knurled nut (185), lock washers (20, 55, 175), washers (35, 70, 95, 155, 170) and wires from hexagonal screws (15, 50, 85) and countersunk screw (165). b Remove hexagonal nuts (30, 65, 100, 150, 180), washers (25, 60, 95, 155, 170), lock washers (20, 55, 90, 175), hexagonal screws (15, 50, 85), countersunk screw (165) and setscrew (140). 2 Disconnect wires from ground stud assy (110) a Remove hexagonal screw (115), lock washer (120), washers (125, 130) and wires. 3 Remove clamps (-220, -225), washers (-230), covers (-190, -195, -200), distance sleeves (-205, -210, -215), conduits (-235, -240) and wire bundle. (b) Remove ground stud brackets (5).
(6)
Electrical system - Unit G6 (refer IPC, fig 8E) (a) Removal of control panel assy (-5) and control module assy (245) 1 Loosen fasteners (15) and remove control module assy (245). 2 Remove cover (270) from control module assy (245). 3 Disconnect control module assy (245) from electrical system. 4 Remove fasteners (15) from control panel (10). 5 Disconnect control panel assy (10) from control module assy (245).
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6 Remove allen screws (25), lock washers (30), washers (35), handles (20) and control panel (10) from control module assy (245). 7 Remove pan-head screws (255), washers (260) and sliding strip (250) from control module assy (245). 8 Pull off adhesive tapes (-265) from control module assy (245) in case of damage only. (b) Electrical components 1 Disconnect wires from electrical components. 2 Removal of plug support assy (335) a Remove pan-head screws (145, fig 6B), washers (150, fig 6B) and plug support assy (335). b Remove pan-head screws (-345) and cover (-340) from plug support assy. 3 Remove circuit breakers (45, 50, 55, 60, 65, 70), toggle switches (75, 80, 85), indicator lights (90, 95, 110), bulbs (105, 110), miniature fuse (120), fuse holder (115), resistor (155) and holder (160) from control panel (245). 4 Remove covers (130, 145, 270), terminal busses (135, 150) and terminal board (125, 140) from control module assy (245). 5 Remove clamps (665, 670, 675, 685), grommet nut (655), plugs (170, 175, 180, 185, 190, 195, 200), receptacles (205, 210, 215, 220, 225, 230), transformer (235), thermostat (240), spring latch (625) and backshells (680). 6 Remove work light (165), timer bracket (290), consoles (295), timer (600), knob (605), casing (615), protecting cover (635) and terminal block (640). (c) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (350, 385, 420, 450, 480, 510, 565) a Remove hexagonal nuts (380, 415, 445, 475, 505, 535, 575), lock washers (360, 395, 440, 470), washers (375, 410, 435, 465, 495, 525, 585) and wires from hexagonal screws (355, 390, 425, 485, 515), pan-head screw (455) and setscrew (570).
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b Remove hexagonal nuts (370, 405, 500, 530, 580), washers (365, 400, 430, 460, 495, 525, 585), lock washers (360, 395, 490, 520), hexagonal screws (355, 390, 425, 485, 515), pan-head screw (455) and setscrew (570). 2 Disconnect wires from ground stud assy (540) a Remove hexagonal screw (545), lock washer (550), washers (555, 560) and wires. 3 Remove clamps (-730, -735), pin (-710), washers (-740), spacers (-745), fasten tap (-610), sockets (-695, -700), terminal lug (-690), distance sleeves (-715, -720, -725), conduits (-750, -755, -760, -765, -770, -775, -780), sleeves (-785, -790, -795, -800, -805, -810), heat tapes (590, 595), soldering sleeves (-705), wire shield (-620) and wire bundle. (d) Remove mounting brackets (275, 280, 285, 300, 305, 310), ground stud brackets (315, 320, 325, 330), rail (645), end clamp (650) and cable bracket (660).
(7)
Electrical system - Unit G7 (refer IPC, fig 8F) (a) Removal of control panel assy (-5) and control module assy (205) 1 Loosen fasteners (15) and remove control module assy (205). 2 Remove cover (230) from control module assy (205). 3 Disconnect control module assy (205) from electrical system. 4 Remove fasteners (15) from control panel (10). 5 Disconnect control panel assy (-5) from control module assy (205). 6 Remove allen screws (25), lock washers (30), washers (35), handles (20) and control panel (10) from control module assy (205). 7 Remove pan-head screws (215), washers (220) and sliding strip (210) from control module assy (205). 8 Pull off adhesive tapes (-225) from control module assy (205) in case of damage only. (b) Electrical components 1 Disconnect wires from electrical components.
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2 Remove circuit breakers (45, 50, 55), toggle switches (60, 65), switch (70), rotary switch (75), indicator lights (80, 85, 90), bulbs (95, 100), fuse holder (105), miniature fuse (110), cover (240) and knob (235) from control panel (10). 3 Remove covers (120, 135), terminal busses (125, 140), terminal boards (115, 130), resistor (145) and holder (150) from control module assy (205). 4 Remove clamps (550, 555, 560, 570), spring latch (520), backshell (565), plugs (155, 160, 165, 170, 175), receptacles (180, 185, 190, 195) and transformer (245). 5 Remove terminal block (525), dummy receptacle (200) and console (-320). (c) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (325, 360, 395, 425, 455) a Remove hexagonal nuts (355, 390, 420, 450, 480), lock washers (335, 370, 415), washers (350, 385, 410, 440, 470) and wires from hexagonal screws (330, 365, 430, 460) and pan-head screw (400). b Remove hexagonal nuts (345, 380, 445, 475), washers (340, 375, 405, 440, 470), lock washers (335, 370, 435, 465), hexagonal screws (330, 365, 430, 460) and pan-head screw (400). 2 Disconnect wires from ground stud assy (485) a Remove hexagonal screw (490), lock washer (495), washers (500, 505) and wires. 3 Remove clamps (-595, -600), pins (-615), spacers (-610), washers sockets (-625, -630, -635) terminal lug (-620), distance sleeves 585, -590), conduits (-640, -645, -650, -655, -660, -665, -670), (-675, -680, -685, -690, -695, -700), heat tape (255), soldering (-575), wire shields (-705, -710) and wire bundle. (d) (-605) (-580, sleeves sleeves
Remove grommet nut (540), thermostat (250), mounting brackets (260, 265, 270, 275, 285, 290), mounting plate (280), ground stud brackets (295, 300, 305, 310, -315), fasten tap (510), protecting cover (515), rail (530), end clamp (535) and cable bracket (545).
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(8)
Electrical system - Unit G4A (refer IPC, fig 8G) (a) Electrical components 1 Disconnect wires from electrical components. 2 Remove work light (10) and console (50). (b) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (65, 100, 140) a Remove hexagonal nuts (95, 135, 165), lock washers (75, 130), washers (90, 125, 155) and wires from hexagonal screws (70, 145) and countersunk screw (105). b Remove hexagonal nuts (85, 120, 160), washers (80, 115, 155), lock washers (75, 150), spacer (110), hexagonal screws (70, 145) and countersunk screw (105). 2 Disconnect wires from ground stud assy (170) a Remove hexagonal screw (175), lock washer (180), washers (185, 190) and wires. 3 Remove clamps (-35, -40), washers (-45), distance sleeves (-20, -25, -30), conduits (-210, -215, -220) pins (-205), jiffy junctions (-195, -200) and wire bundle (-225). (c) Remove bracket (55), cable bracket (15) and ground stud brackets (60).
(9)
Electrical system RH closet unit (refer IPC, fig 8H) (a) Electrical components 1 Disconnect wires from electrical components. 4 Remove plugs (10). 5 Remove covers (20, -25, -30, -35), micros switch (5), spot light (15) and console (85).
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(b)
Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (105, 140, 205) a Remove hexagonal nuts (135, 175, 230), lock washers (115, 170), washers (130, 165, 220) and wires from hexagonal screws (110) and countersunk screws (145, 210). b Remove hexagonal nuts (125, 160, 225), washers (120, 155, 220), lock washer (115), spacers (150, 215), hexagonal screw (110) and countersunk screws (140, 210). 2 Disconnect wires from ground stud assy (180) a Remove hexagonal screw (185), lock washer (190), washers (195, 200) and wires. 3 Remove clamps (-60, -65), washers (-70), distance sleeves (-45, -50, -55), conduits (-75, -80) and wire bundle (-250).
(c) (10)
Remove bracket (90), mounting plate (95), cable bracket (40) and ground stud brackets (100).
Electrical system Door 2 (refer IPC, fig 8J) (a) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (60, 95) a Remove hexagonal nuts (90, 130), lock washers (70, 125), washers (85, 120) and wires from hexagonal screw (65) and countersunk screw (100). b Remove hexagonal nuts (80, 115), washers (75, 110), lock washer (70), spacer (105), hexagonal screws (65) and countersunk screw (100). 2 Disconnect wires from ground stud assy (135) a Remove hexagonal screw (140), lock washer (145), washers (150, 155) and wires. 3 Remove clamps (-35, -40), washers (-45), covers (-5, -10, -15), distance sleeves (-20 ,-25, -30), conduits (-160, -165) and wire bundle (-170).
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(b) (11)
Remove bracket (50) and ground stud brackets (55).
Electrical system AFT partition (refer IPC, fig 8K) (a) Electrical components 1 Disconnect wires from electrical components. 2 Remove pins (-160, 165), plugs (5, 10), spring latch (15), backshell (30) and jiffy junction (-150). (b) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assemblies (80, 115) a Remove hexagonal nuts (110, 145), lock washers (90, 125), washers (105, 140) and wires from hexagonal screws (85, 120). b Remove hexagonal nuts (100, 135), washers (95, 130), lock washers (90, 125) and hexagonal screws (85, 120). 2 Remove clamps (-60, -65), washers (-70), distance sleeves (-45, -50, -55), conduits (-170,- 175, -180), soldering sleeve (-25), shield wires (-205) and wire bundle. (c) Remove protecting covers (20), cable bracket (35), fasten tap (40), ground stud bracket (75) and contact sockets (-155).
(12)
Electrical system - Unit G3/G4 (refer IPC, fig 8L) (a) Electrical components 1 Disconnect wires from electrical components. 2 Remove backshells (20) and plugs (5, 10). 3 Remove fluorescent tubes (35) and ballast units (15).
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(b)
Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assy (80) a Remove hexagonal nut (110), lock washer (90), washer (105) and wire from hexagonal screw (85). b Remove hexagonal nuts (100), washers (95), lock washers (90), hexagonal screws (85). 2 Remove clamps (-50, -55), washers (-45), distance sleeves (-60, -65, -70), conduits (-115, -120, -125, -130) and wire bundle.
(c) (13)
Remove sockets (25, 30) and cable bracket (40).
Electrical system - Unit G6/G7 (refer IPC, fig 8M) (a) Electrical components 1 Disconnect wires from electrical components. 2 Remove clamps (100), backshells (95), plugs (5, 10) and receptacles (15, 20, 25). 3 Remove fluorescent tubes (30, 35), ballast units (60, 65), terminal blocks (40, 45, 50), end clamps (55), rail (85) and console (145). (b) Wire bundle NOTE: In case of defective wires replace applicable wires. It is necessary to remove clamps and cable wrap. 1 Disconnect wires from ground stud assy (170) a Remove hexagonal nut (200), lock washer (180), washer (195) and wire from hexagonal screw (175). b Remove hexagonal nut (190), washer (185), lock washer (180), hexagonal screw (175). 2 Remove clamps (-135, -140), washer (-80), terminal lug (-205), distance sleeves (-120, -125, -130), conduits (-215, -220, -225, -230), soldering sleeves (-210) and wire bundle.
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(c)
Remove grommet nut (115), fasten tab (70), protecting cover (75), sockets (105), contact sockets (110), bracket (165), mounting brackets (150, 155, 160) and cable bracket (90).
G.
Water Installation Assemblies Unit G1, G2, G3, G4, G5, G6, G7 And G4A (1) Water installation assy - Unit G3 (refer IPC, fig 9) (a) (b) Remove bonding clips (390, 395, 400). Removal of manual operation assy (75) 1 Disconnect bowden wire (30, fig 26) and bowden cables (35, 40 fig 26) with end parts (60, fig 26) and bushings (65, fig 26) from bolts (20, fig 26; 50, fig 26). 2 Remove knob (45, fig 26) from bolt (50, fig 26). 3 Remove bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 4 Remove end parts (60, fig 26) from bowden cable (35, fig 26). 5 Remove hexagonal nuts (70, fig 26) and adjusting screw (25, fig 26) from mounting angle (10, fig 26). 6 Remove bowden cable (35, fig 26) with bowden wire (30, fig 26). 7 Remove bushings (65, fig 26) and pull out bowden cable (35, fig 26) from bowden wire (30, fig 26). 8 Pull off operation label (40, fig 26) in case of damage only. 9 Remove countersunk screws (15, fig 26) and bracket (5, fig 26). 10 Remove mounting angle (10, fig 26). (c) Removal of water filter assy (35) 1 Remove hexagonal screws (200), lock washers (225), washers (220), filter supports (50, 55) and water filter assy (35). 2 Remove gasket (-45) and cartridge (-40) from water filter assy (35). NOTE: After replacing of the water filter cartridge in the water filter it must be strictly mandatory that the vent screw of the filter housing has to be positioned at the highest point, to make sure that cpl. water system will be vented and completely drained.
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3 Remove reinforcing rings (60) from water filter assy (35). (d) Remove hexagonal screws (210), washers (220), lpck washers (225), clamps (295, 300, 305, 310), drain valve (20), elbow (80), distance sleeves (230), drain stop T-fitting (240), hoses (255, 260, 265) insulating hoses (275, 280), tubes (330, 335, 340, 345) and foams (410, 415). Remove hexagonal screws (200, 205), washers (200), lock washers (225), clamps (285, 290, 315), shut off valve (25), water spigot (65), elbows (85, 90, 95, 100), double nipples (105, 140, 145), T-fittings (110, 115, 120, 125), coupling nipples (130) with gasket (135), hexagonal nuts (155, 160), sleeves (170, 175), distance sleeves (235), hoses (245, 250) insulating hoses (270, 405) and tubes (320, 325, 350, 355, 360, 365, 370, 375, 380, 385, 390). Remove countersunk screws (185, 190) and mounting brackets (5, 10, 15).
(e)
(f) (2)
Water installation assy - Unit G3 (refer IPC, fig 9) (a) (b) Remove bonding clip (115). Removal of manual operation assy (20) 1 Disconnect bowden wire (30, fig 26) and bowden cable (35, fig 26) with end parts (60, fig 26) and bushings (65, fig 26) from bolts (20, fig 26; 50, fig 26). 2 Remove knob (45, fig 26) from bolt (50, fig 26). 3 Remove bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 4 Remove end parts (60, fig 26) from bowden cable (35, fig 26). 5 Remove hexagonal nuts (70, fig 26) and adjusting screw (25, fig 26) from mounting angle (10, fig 26). 6 Remove bowden cable (35, fig 26) with bowden wire (30, fig 26). 7 Remove bushings (65, fig 26) and pull out bowden cable (35, fig 26) from bowden wire (30, fig 26). 8 Pull off operation label (40, fig 26) in case of damage only. 9 Remove countersunk screws (15, fig 26) and bracket (5, fig 26). 10 Remove hexagonal screws (), lock washers (), washers () and mounting angle (10, fig 26).
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(c)
Remove countersunk screws (75, 80), hexagonal screws (85, 90, 95, 100), washers (105), lock washers (110), clamps (40, 45, 50, 55, 60), adapter (25) distance sleeves (65), drain stop valve (15), elbows (30, 35), T-fitting (70), insulating hoses (135, 140, 145, 150), insulating foams (155, 160, 165, 170), hoses (120, 125, 130) and tubes (175, 180, 185). Remove drain stop valve bracket (10) and mounting brackets (5).
(d) (3)
Water installation assy - Unit G3 (refer IPC, fig 9B) (a) Removal of manual operation assy (20) 1 Disconnect bowden wire (30, fig 26) and bowden cable (35, fig 26) with end parts (60, fig 26) and bushings (65, fig 26) from bolts (20, fig 26; 50, fig 26). 2 Remove knob (45, fig 26) from bolt (50, fig 26) (only for fig 9, 9A, 9C, 9D, 9E, 9G). 3 Remove bolts (20, fig 26; 50, fig 26) and springs (55, fig 26) (only for fig 9, 9A, 9C, 9D, 9E, 9G). 4 Remove end parts (60, fig 26) from bowden cable (35, fig 26). 5 Remove hexagonal nuts (70, fig 26) and adjusting screw (25, fig 26) from mounting angle (10, fig 26). 6 Remove bowden cable (35, fig 26) with bowden wire (30, fig 26). 7 Remove bushings (65, fig 26) and pull out bowden cable (35, fig 26) from bowden wire (30, fig 26). 8 Pull off operation label (40, fig 26) in case of damage only. 9 Remove countersunk screws (15, fig 26) and bracket (5, fig 26). 10 Remove mounting angle (10, fig 26). (b) (c) Remove clamps (70, 75, 80), reducing part (25), drain valve (15), elbow (30), spacers (40), hoses (60 ,65) and tubes (85, 90). Remove countersunk screws (45), washers (50), hexagonal nuts (55) and mounting brackets (5, 10).
(4)
Water installation assy - Unit G4 (refer IPC, fig 9C) (a) Remove bonding clips (190, 195).
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(b)
Removal of manual operation assy (60) 1 Disconnect bowden wire (30, fig 26) and bowden cable (35, fig 26) with end parts (60, fig 26) and bushings (65, fig 26) from bolts (20, fig 26; 50, fig 26). 2 Remove knob (45, fig 26) from bolt (50, fig 26). 3 Remove bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 4 Remove end parts (60, fig 26) from bowden cable (35, fig 26). 5 Remove hexagonal nuts (70, fig 26) and adjusting screw (25, fig 26) from mounting angle (10, fig 26). 6 Remove bowden cable (35, fig 26) with bowden wire (30, fig 26). 7 Remove bushings (65, fig 26) and pull out bowden cable (35, fig 26) from bowden wire (30, fig 26). 8 Pull off operation label (40, fig 26) in case of damage only. 9 Remove countersunk screws (15, fig 26) and bracket (5, fig 26). 10 Remove mounting angle (10, fig 26).
(c)
Removal of water filter assy (25) 1 Remove water filter assy (25). 2 Remove gasket (30) and cartridge (35) from water filter assy (25). NOTE: After replacing of the water filter cartridge in the water filter it must be strictly mandatory that the vent screw of the filter housing has to be positioned at the highest point, to make sure that cpl. water system will be vented and completely drained.
(d) (e)
Remove clamps (170, 180, 185), exhaust valve (50), spacer (165), hoses (215, 220, 225, 230) and tube (265). Remove clamps (175), hexagonal nuts (145, 150, 155, 160), elbows (85, 90, 95, 100), shut off valve (45), water spigot (55), shell (65), plate (70), copling nipple (75), gasket (80), double nipples (105, 110, 115), T-fittings (120, 125, 130, 135), socket (140), hoses (200, 205, 210) and tubes (235, 240, 245, 255, 260). Remove mounting brackets (5, 10, 15, 20).
(g)
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(5)
Water installation assy - Unit G5 (refer IPC, fig 9D) (a) Removal of manual operation assy (25) 1 Disconnect bowden wire (30, fig 26) and bowden cable (35, fig 26) with end parts (60, fig 26) and bushings (65, fig 26) from bolts (20, fig 26; 50, fig 26). 2 Remove knob (45, fig 26) from bolt (50, fig 26). 3 Remove bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 4 Remove end parts (60, fig 26) from bowden cable (35, fig 26). 5 Remove hexagonal nuts (70, fig 26) and adjusting screw (25, fig 26) from mounting angle (10, fig 26). 6 Remove bowden cable (35, fig 26) with bowden wire (30, fig 26). 7 Remove bushings (65, fig 26) and pull out bowden cable (35, fig 26) from bowden wire (30, fig 26). 8 Pull off operation label (40, fig 26) in case of damage only. 9 Remove countersunk screws (15, fig 26) and bracket (5, fig 26). 10 Remove mounting angle (10, fig 26). (b) Remove hexagonal screws (75), lock washers (85), washers (80), clamps (40, 45, 50), distance sleeves (55, 60), drain stop valve (20), reducing part (30), elbow (35), hoses (90, 95) and tubes (100, 105, 110). Remove countersunk screws (65), hexagonal screws (70), lock wahers (85), washers (80), bracket (10), drain stop valve bracket (15) and mounting brackets (5).
(c)
(6)
Water installation assy - Unit G6 (refer IPC, fig 9E) (a) (b) Remove bonding clips (190, 195, 200). Removal of manual operation assy (60) 1 Disconnect bowden wire (30, fig 26) and bowden cable (35, fig 26) with end parts (60, fig 26) and bushings (65, fig 26) from bolts (20, fig 26; 50, fig 26). 2 Remove knob (45, fig 26) from bolt (50, fig 26). 3 Remove bolts (20, fig 26; 50, fig 26) and springs (55, fig 26).
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4 Remove end parts (60, fig 26) from bowden cable (35, fig 26). 5 Remove hexagonal nuts (70, fig 26) and adjusting screw (25, fig 26) from mounting angle (10, fig 26). 6 Remove bowden cable (35, fig 26) with bowden wire (30, fig 26). 7 Remove bushings (65, fig 26) and pull out bowden cable (35, fig 26) from bowden wire (30, fig 26). 8 Pull off operation label (40, fig 26) in case of damage only. 9 Remove countersunk screws (15, fig 26) and bracket (5, fig 26). 10 Remove hexagonal screws (210), lock washers (230), washers (235) and mounting angle (10, fig 26). (c) Removal of water filter assy (25) 1 Remove hexagonal screws (210), lock washers (230), washers (235), filter supports (40, 45) and water filter assy (25). 2 Remove gasket (-30) and cartridge (-35) from water filter assy (25). NOTE: After replacing of the water filter cartridge in the water filter it must be strictly mandatory that the vent screw of the filter housing has to be positioned at the highest point, to make sure that cpl. water system will be vented and completely drained. 3 Remove reinforcing rings (50) from water filter assy (25). (d) Remove hexagonal screws (210, 220), lock washers (230), washers (235), spacer (145), clamps (150, 155, 165, 170), drain valve (55), elbow (105), T-fittings (110), insulating hoses (290), hoses (260, 265, 270, 275), sealing tapes (350) and tubes (300, 310, 315, 320). Remove hexagonal screws (220), lock washers (230), washers (235), clamps (160), hexagonal nuts (135, 140), shut off valve (65), water spigot (70), exhaust valve (75), double nipples (80, 85), elbows (90, 95, 100), sleeves (175, 180), distance sleeves (185), T-fittings (115, 120, 125, 130), hoses (245, 250, 250, 285) and tubes (-305, -325, 330, 335, 340, 345). Remove countersunk screws (225), hexagonal screws (215), pan-head screws (205), washer (240), coffee maker rail (295) and mounting brackets (5, 10, 15, 20).
(e)
(f)
(7)
Water installation assy - Unit G7 (refer IPC, fig 9F) (a) Remove bonding clips (120, 125).
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(b)
Remove hexagonal nuts (100), lpck washers (105), washers (110), spacers (115), clamps (70), shut off valve (15), exhaus valve (20), coupling nipples (25) with gasket (30), double nipples (35, 40, 45), elbows (50, 55), T-fittings (60), fitting (65), hexagonal nuts (75, 80, 85), sleeves (90), hose (130), insulating hose (135) sealing tape (140) and tubes (145, 150, 155, 160, 165, 170, 175, 180). Remove hexagonal screws (95), lock washers (105), washers (110) and mounting brackets (5, 10).
(c) (8)
Water installation assy - Unit G4A (refer IPC, fig 9G) (a) Removal of manual operation assy (20) 1 Disconnect bowden wire (30, fig 26) and bowden cable (35, fig 26) with end parts (60, fig 26) and bushings (65, fig 26) from bolts (20, fig 26; 50, fig 26). 2 Remove knob (45, fig 26) from bolt (50, fig 26). 3 Remove bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 4 Remove end parts (60, fig 26) from bowden cable (35, fig 26). 5 Remove hexagonal nuts (70, fig 26) and adjusting screw (25, fig 26) from mounting angle (10, fig 26). 6 Remove bowden cable (35, fig 26) with bowden wire (30, fig 26). 7 Remove bushings (65, fig 26) and pull out bowden cable (35, fig 26) from bowden wire (30, fig 26). 8 Pull off operation label (40, fig 26) in case of damage only. 9 Remove countersunk screws (15, fig 26) and bracket (5, fig 26). 10 Remove mounting angle (10, fig 26). (b) (c) Remove clamps (55, 60, 65), drain valve (15), adapter (25), spacer (30) and hoses (35, 40, 45, 50,70, 75). Remove mounting brackets (5, 10).
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H.
Ventilation Systems - Unit G1, G4, G6 And G7 (1) Ventilation system Unit G3 (refer IPC, Fig 10) (a) (b) (c) (d) Remove cap (10), bushing (15), clamp (20) and air outlet (5) from hose (25). Remove pan-head screws (40), washer (45), clamps (35, 55), distance sleeve (50), sleeve (30) and hose (25) from airplane supply system. Remove pan-head screws (40), washers (45), clamps (75, 175), brackets (95), sleeve (70) and hose (100) from air flap assy (95). Removal of air flap assy (105) 1 Remove bracket (95), clamp (75) and air flap assy (105) from hose (90). 2 Remove pan-head screw (120), countersunk screw (135), washers (125, 140, 145), handle (115) and air flap (110) from tube (130). (e) (f) (g) (h) (i) (2) Remove pan-head screws (40), washers (45), clamp (75), bracket (95), sleeve (70) and hose (90) from hose (80). Remove clamps (75) and hose (80) from hose (65) and from bracket (95). Remove pan-head screws (40), washers (45), bracket (95), sleeve (70), hose (85), clamp (75) and tube (60) from elbow (150). Remove hose (65), sleeve (70), clamp (75), pan-head rivet (180) and tube (60) from air duct. Remove pan-head screws (40), washers (45), brackets (165), clamps (170), elbow (150) sleeve (160) and hose (155) from airplane supply system.
Ventilation system Unit G4 (refer IPC, Fig 10A) (a) (b) (c) (d) (e) Remove clamp (80), cap (125), bushing (125) and air outlet (5) from hose (115). Remove clamp (80), sleeve (85) and hose (115) from airplane supply system. Remove clamps (75), sleeves (90) and hose (100) from T-fitting (10) and from airplane supply system. Remove pan-head screws (20), washers (25), support (15), clamps (75), sleeve (90), hose (95) and t-fitting (10) from support (15). Remove pan-head screws (20), washers (25), support (15), hose (105) and clamps (75) from air flap assy (30).
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(f)
Removal of air flap assy (30) 1 Remove air flap assy (30) and clamp (75) from hose (105). 2 Remove pan-head screw (45), countersunk screw (60), washers (50, 65, 70) handle (40) and air flap (35) from tube (55).
(g) (3)
Remove hose (110) and clamp (75) from air duct.
Ventilation system Unit G6 (refer IPC, fig 10B) (a) (b) (c) (d) Remove bushing (10) and air outlet (5) from hose (110). Remove pan-head screws (25), washers (30), support (20), clamps (85, 90), sleeve (100) and hose (110) from airplane supply system. Remove clamps (80, 95), pan-head screw (25), washer (30), supports (15), clamp (95), sleeve (105) and hose (120) from air flap assy (35). Removal of air flap assy (35) 1 Remove clamp (95) and air flap assy (35) from support (15). 2 Remove pan-head screw (50), countersunk screw (65), washers (55, 70, 75), handle (45) and air flap (40) from tube (60). (e) (f) (g) (h) Remove pan-head screws (25). washers (30), support (15), sleeve (105), hoses (115, 130) and clamps (80, 95) from airplane supply system. Remove pan-head screws (25), washers (30), supports (15), clamps (80, 95), sleeve (105) and hose (135) from air flap assy (35). Remove air flap assy (35) from support (15). Remove pan-head screws (25), washers (30), support (15), clamps (80) sleeve (105) and hoses (125, 130) from airplane supply system.
(4)
Ventilation system Unit G7 (refer IPC, fig 10C) (a) (b) (c) (d) Remove bushing (10), clamp (95) and air outlet (5) from hose (115). Remove pan-head screws (20), washers (25), clamps (85, 90), sleeve (105) and hose (115) from airplane supply system. Remove clamps (80), sleeve (110) and hose (120) from air flap assy (35). Removal of air flap assy (35) 1 Remove clamp (80) and air flap assy (35) from support (15).
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2 Remove pan-head screw (50), countersunk screw (65), washers (55, 70, 75), handle (45) and air flap (40) from tube (60). (e) (f) (g) Remove pan-head screws (20), washers (25), supports (15), sleeve (110) and hose (130) from T-fitting (30). Remove pan-head screws (20), washers (25), supports (15), clamps (100), sleeve (110) and hose (125) from T-fitting (30). Remove T-fitting (30), clamps (100), sleeve (110) and hose (135) from air duct.
I.
Cooling Systems - Unit G2, G4, G6 And G7 (1) Cooling system - Unit G2 (refer IPC, fig 11) (a) (b) Remove clamps (145) and hoses (135, 140) from air duct assy (40) and from airplane supply system. Removal of air duct assy (40) 1 Remove pan-head screws (125). washers (130) and air duct assy (40). 2 Remove pan-head screws (50), washers (55), supports (45) from air duct assy (40). 3 Pull off sealing tapes (60) from air duct assy (40) in case of damage only. (c) Removal of air baffle assemblies (65, 95) 1 Remove pan-head screws (125), washers (130) and air baffle assemblies (65, 95). 2 Remove pan-head screws (80, -110), hexagonal nuts (90, -120), washers (85, -115), extrusions (70, -100) and sealing profiles (75, -105) from air baffle assemblies (65, 95). (d) Removal of air baffle assy (150) 1 Remove pan-head screws (125), washers (130) and air baffle assy (150). 2 Remove extrusion (155) from air baffle assy (150). (e) Removal of air duct assy (5) 1 Remove pan-head screws (125), washers (130) and air duct assy (5).
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2 Remove pan-head screws (15), washers (20) and supports (10) from air duct assy (5). 3 Pull off sealing tapes (35) from air duct assy (5) in case of damage only. (f) (g) (h) (2) Remove countersunk screws (170) and air grid (165). Remove plate (160) and extrusion (185). Pull off sealing profile (180) and shim (175) in case of damage only.
Cooling system - Unit G4 (refer IPC, fig 11A) (a) Removal of air duct assemblies (5, 65) 1 Remove pan-head screws (135) and air duct assemblies (5, 65). 2 Remove pan-head screws (15, 75) and supports (10, 70) from air duct assemblies (5, 65). 3 Remove countersunk screws (25, 85) and air grids (20, 80) from air duct assy (5). 4 Pull off shims (30, 90) from air duct assemblies (5, 65). (b) Removal of bellow assemblies (35, 95) 1 Remove hexagonal screws (140), washers (145) and bellow assemblies (35, 95). 2 Remove pan-head screws (55, 115), washers (60, 120), bellows (40, 100), flanges (45, 105) and frames (50, 110) from bellow assemblies (35, 95). (c) (d) Remove air baffle (130). Pull off shim (125) in case of damage only.
(3)
Cooling system - Unit G6 (refer IPC, fig 11B) (a) (b) Remove clamps (185) and hoses (175, 180) from air duct assemblies (5, 35) and from connection tube assemblies (140, 155). Removal of air duct assemblies (5, 30, 50, 70, 90) 1 Remove pan-head screws (110), washers (115) and air duct assemblies (5, 30, 50, 70, 90).
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2 Remove pan-head screws (15, 40, 60, 80, 100) and supports (10, 35, 55, 75, 95) from air duct assemblies (5, 30, 50, 70, 90). 3 Pull off sealing tapes (20, 25, 45, 65, 85, 105) from from air duct assemblies (5, 30, 50, 70, 90) in case of damage only. (c) (d) Remove pan-head screws (110), washers (115) and air grids (120, 125, 130, 135). Removal of connection tube assemblies (140, 155) 1 Remove hexagonal screws (165), washers (170) and connection tube assemblies (140, 155). 2 Pull off sealing tapes (145, 160) and foam plates (150) from tube assemblies (140, 155) in case of damage only. (e) Removal of air baffle assemblies (190, 220) 1 Remove pan-head screws (110), washers (115) and air baffle assemblies (190, 220). 2 Remove pan-head screws (205, -235), hexagonal nuts (215, -245), washers (210, -240), extrusions (195, -225) and sealing profiles (200, -230) from air baffle assemblies (190, 220). (f) (4) Remove plate (250).
Cooling system - Unit G7 (refer IPC, fig 11C) (a) (b) Remove clamps (165) and hoses (155, 160) from air duct assemblies (5, 30) and from connection tube assemblies (120, 135). Removal of air duct assemblies (5, 30, 55, 75) 1 Remove pan-head screws (90), washers (95) and air duct assemblies (5, 30, 55, 75). 2 Remove pan-head screws (15, 40, 65, 85) and supports (10, 35, 60, 80) from air duct assemblies (5, 30, 55, 75). 3 Pull off sealing tapes (20, 25, 45, 50, 70) from air duct assemblies (5, 30, 55, 75) in case of damage only. (c) Remove pan-head screws (90), washers (95) and air grids (100, 105, 110, 115).
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(d)
Removal of connection tube assemblies (120, 135) 1 Remove hexagonal screws (145), washers (150) and connection tube assemblies (120, 135). 2 Pull off sealing tapes (125, 140) and foam plates (130) from connection tube assemblies (120, 135) in case of damage only.
(e)
Removal of air baffle assemblies (170, 200) 1 Remove pan-head screws (90), washers (95) and air baffle assemblies (170, 200). 2 Remove pan-head screws (185, -215), hexagonal nuts (195, -225), washers (190, -220), extrusions (175, -205) and sealing profiles (180, -210) from air baffle assemblies (170, 200).
J.
Decorative Materials - Unit G1, G2, G3, G4, G5, G6, G7, G4A, RH Closet And Door 2 (1) Decorative materials - Unit G1 (refer IPC, fig 13) (a) (b) (c) (d) (e) (f) (2) Remove countersunk screws (15, 20), support (25) and pelmet (10). Remove filling strip (40) from protecting strip (35). Remove pan-head screws (50), end parts (45) and protecting strip (35). Remove decorative strip (65) from extrusion (55). Remove countersunk screws (20, 60), extrusions (55, 70), metal sheets (85, 90), sealing profile (95), shims (75, 80) and decor panel (5). Pull off kick strip (30), sliding strips (100, 105, 110, 115, 130, 135), shims (80, 120, 125) and decorative materials (140) in case of damage only.
Decorative materials - Unit G2 (refer IPC, fig 13A) (a) (b) (c) (d) Remove pelmet (75). Remove decorative strips (70) from extrusions (35, 40, 55, 60). Remove filling strips (85) from protecting strips (80). Remove pan-head screws (95), end parts (90) and protecting strips (80).
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(e)
Removal of decor panel assemblies (5, 15, 25) 1 Remove countersunk screws (50, 65), extrusions (35, 40, 55, 60), spacers (45) and decor panel assemblies (5, 15, 25). 2 Pull off sealing profiles (10, 20, 30) from decor panel assemblies (5, 15, 25) in case of damage only.
(f) (3)
Pull off kick strips (100, 105), sliding strips (110, 115, 120) and decorative materials (125) in case of damage only.
Decorative materials - Unit G3 (refer IPC, fig 13B) (a) Removal of decor panel assemblies (5, 40) 1 Remove countersunk screws (75) and decor panel assemblies (5, 40). 2 Remove filling strips (20, 55) from protecting strips (15, 50). 3 Remove pan-head screws (30, 65), end parts (25, 60) and protecting strips (15, 50). 4 Pull off kick strips (10, 45) and sealing profiles (35, 70) from decor panel assemblies (5, 40) in case of damage only. (b) (c) Remove extrusion (90)and shim (85). Pull off kick strip (80) and decorative materials (95, 100, 105) in case of damage only.
(4)
Decorative materials - Unit G4 (refer IPC, fig 13C) (a) Removal of decor panel assemblies (15, 60) 1 Remove countersunk screws (50) and decor panel assemblies (15). 2 Remove filling strips (35) from protecting strips (30). 3 Remove pan-head screws (45, 90), end parts (40, 85) and protecting strips (30, 75). 4 Pull off kick strips (20, -65) and sealing profiles (25, -70) from decor panel assemblies (15, 60) in case of damage only. (b) Remove decor panel assy (5) 1 Remove decor panel assy (5).
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2 Pull off kick strip (10) from decor panel assy (5) in case of damage only. (c) (5) Pull off kick strip (75), adhesive tapes (80) and decorative materials (-85, 90, 95, 100) in case of damage only.
Decorative materials - Unit G5 (refer IPC, fig 13D) (a) (b) (c) (d) (e) (f) Remove filling strips (75) from protecting strips (70). Remove pan-head screws (85), washers (90), end parts (80) and protecting strips (70). Remove mirror (115). Remove decorative strips (35, 65) from extrusions (20, 40, 45, 50, 55). Remove countersunk screws (30, 60), extrusions (20, 40, 45, 50, 55), spacers (25) and decor panels (5, 10, 15). Removal of cover assy (105) 1 Pull off sealing profile (110) from cover assy (105) in case of damage only. (g) (h) Remove countersunk screws (60) and paper clip (135). Pull off kick strips (95, -100), sliding strips (120, 125, 130, 150), sealing profiles (140, 145) and decorative materials (155, 160, 165) in case of damage only.
(6)
Decorative materials - Unit G6 (refer IPC, fig 13E) (a) (b) (c) Remove decorative strips (55, 65) from extrusions (40, 60). Remove pan-head screws (25, 30), washers (35) and decorative panel (20). Removal of decorative panel assy (5) 1 Remove countersunk screws (50), extrusions (40, 60), spacers (45) and decorative panel assy (5). 2 Pull off sealing profiles (10, 15) from decorative panel assy (5) in case of damage only. (d) Pull off sliding strips (70, 75, 80, 85, 90, 95, -100, 105, 110, 115, 120, 125), shims (130, 135, 140, 145), teflons (150), foams (155) and decorative materials (160, 165) in case of damage only.
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(7)
Decorative materials - Unit G7 (refer IPC, fig 13F) (a) (b) (c) (d) Remove decorative strips (55, 65) from extrusions (40, 60). Remove mirror (115). Remove pan-head screws (25, 30), washers (35) and decorative panel (20). Removal of decorative panel assy (5) 1 Remove countersunk screws (50), extrusions (40, 60), spacers (45) and decorative panel assy (5). 2 Pull off sealing profiles (10, 15) from decorative panel assy (5) in case of damage only. (e) Pull off sliding strips (70, 75, 80, 85, 90, 95, 100, -105), shims (110), foam (120) and decorative materials (125, 130) in case of damage only.
(8)
Decorative materials - Unit G4A (refer IPC, fig 13G) (a) Remove countersunk screws (10, 15) and pelmet (5).
(b) Pull off kick strips (20, 25) and decorative materials (30, 35, 40, 45) in case of damage only. (9) Decorative materials - RH Closet (refer IPC, fig 13H) (a) Removal of pelmet complete assy (-55) 1 Removal of pelmet assy (60) a Remove countersunk screws (95, 100) and pelmet assy (60). b Remove panel (65) from pelmet assy (60). c Remove pan-head screws (85), washers (90), support (70) and velcros (75, 77) from pelmet assy (60). 2 Pull off sealing profiles (80) from complete pelmet assy (-55). (b) (c) Remove countersunk screws (35), extrusions (25), sealing profiles (20) and shims (30). Pull off kick strips (5, 10, 15), foam plates (40, -45, 50) and decorative materials (105, 110) in case of damage only.
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(9)
Decorative materials - Door 2 (refer IPC, fig 13J) (a) Removal of pelmet assy (5) 1 Remove countersunk screws (80) and pelmet assy (5). 2 Remove countersunk screws (15) and sealing profile (10) from pelmet assy (5). (b) (c) (d) Remove countersunk screws (75), extrusions (50, -55, 60), sealing profiles (25, 30) and shims (40, 45). Remove countersunk screws (70), extrusions (65) and sealing profile (35). Pull off kick strips (20) and decorative materials (85, 90) in case of damage only.
K.
Door Assemblies (1) Door assy (refer IPC, fig 14) (a) (b) (c) (2) Remove countersunk screws (10), washers (15) and hinge (5) from door. Remove countersunk screws (25) and latch (20) from door. Pull off sliding strip (30) from door in case of damage only.
Door assy (refer IPC, fig 14A) (a) (b) Remove countersunk screws (10), washers (15) and hinge (5) from door. Remove countersunk screws (25) and latch (20) from door.
(3)
Door assy (refer IPC, fig 14B) (a) (b) Remove countersunk screws (15), hinges (5) and covers (10) from door. Remove countersunk screws (25) and latch (20) from door.
(4)
Door assy (refer IPC, fig 14C) (a) (b) Remove pan-head screws (10) and hinge (5) from door. Remove countersunk screws (20) and latch (15) from door.
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(5)
Door assy (refer IPC, fig 14D) (a) (b) (c) (d) (e) (f) Remove countersunk screws (10) and hinge (5) from door. Remove countersunk screws (20) and latch (15) from door. Remove filling strip (35) from protecting strip (30). Remove pan-head screws (45), end parts (40) and protecting strip (30) from door. Remove pan-head screws (60), extrusion (50) and shim (55) from door. Pull off kick strip (25) from door in case of damage only.
(6)
Door assy (refer IPC, fig 14E) (a) (b) (c) (d) (e) Remove countersunk screws (10) and hinge (5) with springs (15) from door. Remove countersunk screws (25) and latch (15) from door. Remove filling strip (40) from protecting strip (35). Remove pan-head screws (50), end parts (45) and protecting strip (35) from door. Pull off kick strip (30), bumpers (55) and shims (60) from door in case of damage only.
(7)
Door assy (refer IPC, fig 14F) (a) (b) (c) (d) (e) (f) Remove countersunk screws (15), hinges (5) and covers (10) from door. Remove countersunk screws (25) and latch (20) from door. Remove countersunk screws (60, -60A, 65, -65A) and bumpers (55, -55A) from door. Remove filling strip (40) from protecting strip (35). Remove pan-head screws (50), end parts (45) and protecting strip (35) from door. Pull off kick strip (30) from door in case of damage only.
(8)
Door assy (refer IPC, fig 14G) (a) Remove countersunk screws (15), hinges (5) and covers (10) from door.
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(b) (c) (d) (e) (9)
Remove countersunk screws (25) and latch (20) from door. Remove filling strip (40) from protecting strip (35). Remove pan-head screws (50), end parts (45) and protecting strip (35) from door. Pull off kick strip (30) from door in case of damage only.
Door assy (refer IPC, fig 14H) (a) (b) (c) (d) (e) (f) (g) Remove pan-head screws (10) and hinge (5) from door. Remove countersunk screws (20) and grip (15) from door. Remove countersunk screws (40), spacers (35), shims (30) and bumpers (25) from door. Remove filling strip (55) from protecting strip (50). Remove pan-head screws (65), end parts (60) and protecting strip (50) from door. Remove countersunk screws (75) and washers (70) from door. Pull off kick strip (45) from door in case of damage only.
(10)
Door assy (refer IPC, fig 14J) (a) Removal of waste flap assy (60) 1 Remove countersunk screws (85) and waste flap assy (60) from door. 2 Drill out countersunk rivets (-80) and remove hinge (-70) with springs (-75) from waste flap (-65). (b) (c) (d) (e) (f) (g) Remove countersunk screws (15), hinges (5) and covers (10) from door. Remove countersunk screws (120) and plates (110, 115) from door. Drill out countersunk rivets (105) and remove extrusion (100) from extrusion (125). Remove pan-head rivets (130) and extrusion (125) from door. Remove countersunk screws (30) and latch (20) from door. Remove filling strip (45) from protecting strip (40).
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(h) (i) (j) (11)
Remove pan-head screws (55), end part (50) and protecting strip (40) from door. Remove countersunk screws (30) and latch (25) from door. Pull off kick strip (35), bumpers (90), shims (95) and sealing profiles (135) from door in case of damage only.
Door assy (refer IPC, fig 14K) (a) (b) (c) (d) (e) (f) (g) Remove countersunk screws (15), hinges (5) and covers (10) from door. Remove countersunk screws (30) and latches (20, 25) from door. Remove filling strip (45) from protecting strip (40). Remove pan-head screws (55), end parts (50) and protecting strip (40) from door. Remove pan-head screws (65) and extrusion (60) from door. Remove pan-head screws (80), extrusion (70) and teflon (75) from door. Pull off kick strip (35) from door in case of damage only.
(12)
Door assy (refer IPC, fig 14L) (a) (b) (c) Remove pan-head screws (10) and hinge (5) from door. Drill out countersunk rivets (30) and remove closing cap (25) from door. Remove fasteners (15) and plates (20) from door.
(13)
Door assy (refer IPC, fig 14M) (a) (b) Remove countersunk screws (10), washers (15) and hinge (5) from door. Remove countersunk screws (25) and latch (20) from door.
(14)
Door assy (refer IPC, fig 14N) (a) (b) (c) (d) Remove pan-head screws (10) and hinge (5) from door. Remove countersunk screws (-10A), washers (15) and hinge (-5A) from door. Remove countersunk screws (25) and latch (20) from door. Remove countersunk screws (35) and grip (30) from door.
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(e) (15)
Remove pan-head screws (50), washers (55), bracket (40) and shim (45) from door.
Door assy (refer IPC, fig 14P) (a) (b) Remove countersunk screws (10), washers (15) and hinge (5) from door. Remove countersunk screws (30) and latches (20, 25) from door.
(16)
Door assy (refer IPC, fig 14Q) (a) (b) (c) Remove countersunk screws (15), hinges (5) and covers (10) from door. Remove countersunk screws (25) and latch (20) from door. Pull off bumpers (30) from door in case of damage only.
(17)
Door assy (refer IPC, fig 14R) (a) (b) Remove countersunk screws (10), washers (15) and hinges (5) from door. Remove countersunk screws (25) and latch (20) from door.
(18)
Door assy (refer IPC, fig 14S) (a) (b) (c) (d) (e) Remove pan-head screws (10) and hinge (5) from door. Remove countersunk screws (20) and latch (15) from door. Remove filling strip (30) from protecting strip (25). Remove pan-head screws (40), end parts (35) and protecting strip (25) from door. Pull off kick strip (45) from door in case of damage only.
(19)
Door assy (refer IPC, fig 14T) (a) (b) Remove pan-head screws (10) and hinge (5) with bumper (15) from door. Remove countersunk screws (25) and latch (20) from door.
(20)
Folding door assy (refer IPC, fig 14U) (a) (b) Remove pan-head screws (20) and hinge (5) from folding door. Remove pan-head screws (20), hinge (10) and shims (15) from folding door.
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(c) (d) (e) (f) (g) (h) (i) L.
Remove countersunk screws (35), extrusions (25) and sealing profile (30) from folding door. Remove countersunk screws (45) and grip (40) from folding door. Remove countersunk screws (55) and washers (50) from folding door. Remove countersunk screws (75), bumpers (60), spacers (70) and shims (65) from folding door. Remove filling strips (85, 95) from protecting strips (80, 90). Remove pan-head screws (105), end parts (100) and protecting strips (80, 90) from folding door. Pull off kick strips (110, 115) from folding door in case of damage only.
Insulated Door Assemblies (1) Insulated door assy (refer IPC, fig 15) (a) (b) (c) (d) (2) Remove countersunk screws (10), washers (15) and hinge (5) with bumpers (30) from insulated door. Remove countersunk screws (25) and latch (20) from insulated door. Remove pan-head screws (55), extrusions (50) and sealing profiles (45) from insulated door. Pull off sliding strip (30) and shim (40) from insulated door in case of damage only.
Insulated door assy (refer IPC, fig 15A) (a) (b) (c) (d) Remove countersunk screws (20), washers (25) and hinges (5, 10) with bolt (15) from insulated door. Remove countersunk screws (35) and latch (30) from insulated door. Remove pan-head screws (60), extrusions (55) and sealing profiles (50) from insulated door. Pull off sliding strips (40) and shims (45) from insulated door in case of damage only.
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(3)
Insulated door assy (refer IPC, fig 15B) (a) (b) (c) (c) (d) (e) (f) (g) (h) (i) Remove pan-head screws (10) and hinge (5) from insulated door. Remove pan-head screws (95), washers (100, 100A), extrusion (90), sealing profile (80) and shim (85) from insulated door. Remove pan-head screws (120), washers (100, 150) extrusion (125), brush (130) and shim (135) from insulated door. Pull off sliding strip (70) and shim (75) from insulated door in case of damage only. Remove pan-head screws (65A, 120), washers (100, 150), extrusion (105), brush (110) and shim (115) from insulated door. Remove countersunk screws (30) and washers (25) from insulated door. Remove countersunk screws (20) and grip (15) from insulated door. Remove countersunk screws (45), bumpers (35) and shims (40, 145) from insulated door. Remove filling strip (55) from protecting strip (50). Remove pan-head screws (65), washers (100A), end parts (60) and protecting strip (50) from insulated door.
(4)
Insulated door assy (refer IPC, fig 15C) (a) Removal of brush assy (-120) 1 Remove pan-head screws (140), washers (145) extrusion (125), brush (130) and shims (135, 150) from insulated door. (b) Removal of brush assy (-155) 1 Remove pan-head screws (175), extrusion (160), brush (165) and shims (170, 180) from insulated door. (c) (d) (e) (f) Remove countersunk screws (30), washers (210) and hinges (5, 10, 15, 20) with bolt (25) from insulated door. Remove pan-head screws (110), washers (115), extrusion (100), sealing profile (95) and shim (105) from insulated door. Remove extrusions (200), plate (195) and shim (190) from insulated door. Remove countersunk screws (50) and washers (45) from insulated door.
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(g) (h) (i) (j) (k) (5)
Remove countersunk screws (40) and grip (35) from insulated door. Remove countersunk screws (70), bumpers (55) and shims (60, 65) from insulated door. Remove filling strip (80) from protecting strip (75). Remove pan-head screws (90), end parts (85) and protecting strip (75) from insulated door. Pull off shim (185) and kick strip (205) from insulated door in case of damage only.
Insulated folding door assy (refer IPC, fig 15D) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Remove pan-head screws (20) and hinge (5) from insulated folding door. Remove pan-head screws (20), hinge (10) and shims (15) from insulated folding door. Remove countersunk screws (35), extrusion (25) and sealing profile (30) from insulated folding door. Remove pan-head screws (140), washers (145), extrusion (130), sealing profile (125) and shim (135) from insulated folding door. Remove pan-head screws (165), washers (145), extrusion (150), brush (155) and shim (160) from insulated folding door. Remove countersunk screws (55) and washers (50) from insulated folding door. Remove countersunk screws (45) and grips (40) from insulated folding door. Remove filling strips (80, 90) from protecting strips (75, 85). Remove pan-head screws (100), protecting strips (75, 85) and end parts (100) from insulated folding door. Remove countersunk screws (70), bumpers (60) and shims (65) from insulated folding door. Remove pan-head screws (165), washers (145), extrusions (170, 185), brushes (175, 190) and shims (180, 195) from insulated folding door. Pull off sliding strips (105, 115), shims (110, 120) and kick strips (200, 205) from insulated folding door in case of damage only.
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(6)
Insulated folding door assy (refer IPC, fig 15E) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Remove pan-head screws (20) and hinge (5) from insulated folding door. Remove countersunk screws (35), extrusion (25) and sealing profile (30) from insulated folding door. Remove pan-head screws (20), shims (15) and hinge (10) from insulated folding door. Remove pan-head screws (140), washers (145), extrusion (130), sealing profile (125) and shim (135) from insulated folding door. Remove pan-head screws (100), washers (145), extrusion (150), brush (155) and shim (160) from insulated folding door. Remove countersunk screws (55) and washers (50) from insulated folding door. Remove countersunk screws (45) and grips (40) from insulated folding door. Remove filling strips (80, 90) from protecting strips (75, 85). Remove pan-head screws (100), washers (145), protecting strips (75, 85) and end parts (95) from insulated folding door. Remove countersunk screws (70), shims (65, 165) and bumpers (60) from insulated folding door. Remove pan-head screws (100), washers (145), extrusions (170, 185), brushes (175, 190) and shims (180, 195) from insulated folding door. Pull off sliding strips (105, 115) shims (110, 120) and kick strips (200, 205) from insulated folding door in case of damage only.
(7)
Insulated folding door assy (refer IPC, fig 15F) (a) Removal of brush assy (-120) 1 Remove pan-head screws (140), washers (145), extrusion (125), brush (130) and spacer (135) from insulated folding door. (b) Removal of brush assy (-150) 1 Remove pan-head screws (175), washers (145), extrusion (155), brushes (160) and shims (165) from insulated folding door. (c) Remove pan-head screws (30) and hinge (5) from insulated folding door.
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(d) (e) (f) (g) (h) (i) (j) (k) (8)
Remove pan-head screws (25), hinge (10), sealing profile (15) and spacers (20) from insulated folding door. Remove countersunk screws (115), extrusion (105), sealing profile (100) and spacer (110) from insulated folding door. Remove countersunk screws (65) and washers (60) from insulated folding door. Remove countersunk screws (40) and grip (35) from insulated folding door. Remove countersunk screws (55), bumpers (45) and shims (50) from insulated folding door. Remove filling strips (75, 85) from protecting strips (70, 80). Remove pan-head screws (95), protecting strips (70, 80) and end parts (90) from insulated folding door. Pull off shims (170) and kick strips (180, 185) from insulated folding door in case of damage only.
Insulated folding door assy (refer IPC, fig 15G) (a) Removal of brush assy (-130) 1 Remove pan-head screws (150), washers (125), extrusion (135), brush (140) and shim (145) from insulated folding door. (b) (c) (d) (e) (f) (g) (h) (i) Remove pan-head screws (150), washers (125), extrusions (160), brushes (165) and shims (170, 180) from insulated folding door. Remove countersunk screws (230), washers (235), hinges (5, 10, 15, 20) and bolt (25) from insulated folding door. Remove countersunk screws (50), extrusion (45) and sealing profile (40) from insulated folding door. Remove countersunk screws (35), hinge (30), spacers (235) and shims (115) from door. Remove pan-head screws (120), washers (125), extrusion (110), sealing profile (105) and shim (115) from insulated folding door. Remove countersunk screws (50) and washers (65) from insulated folding door. Remove countersunk screws (60) and grip (55) from insulated folding door. Remove countersunk screws (155), bumper (70) and shims (75, 80) from insulated folding door.
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(j) (k) (l)
Remove filling strips (90) from protecting strips (85). Remove pan-head screws (100), protecting strips (85) and end parts (95) from insulated folding door. Pull off shims (175, 185), plates (190, 205), sealing profiles (195), shims (200, 210) and kick strips (220, 225) from insulated folding door in case of damage only.
M.
Roller Blind Assy (1) (2) Roller blind assy (refer IPC, fig 16) Removal of roller blind lock assy (5) (a) (b) (c) (d) (e) Remove pan-head screws (60) and cover (105) from roller blind lock assy (5). Remove countersunk screws (35), washers (30) and knobs (25) from sliders (65). Remove adapter sleeves (95), rods (70, 75, 80, 85), spring (90) and sliders (65) from brackets (40, 45, 50). Remove countersunk screws (55) and brackets (40) from shell (15). Remove countersunk screws (20) and shell (15) from roller blind lock assy (5).
N.
Drawer Assemblies (1) Ice drawer assy (refer IPC, fig 17) (a) (b) (c) Remove sieve (50) from ice bin (30). Remove countersunk screw (40), knurled nut (35), hexagonal nut (45) and ice bin (30) from casing (20). Removal of front panel assy (5) 1 Remove pan-head screws (25) and front panel assy (5) from casing (20). 2 Remove countersunk screws (15) and latch (10) from front panel assy (5). (d) Remove countersunk screws (60) and rail guides (55) from casing (20).
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(2)
Drawer assy (refer IPC, fig 17A) (a) Removal of ice bin assy (40). 1 Remove countersunk screw (55), knurled nut (50), hexagonal nut (60) and ice bin assy (40) from casing (30). 2 Remove sieve (45) from ice bin assy (40). (b) Removal of front panel assy (5) 1 Remove pan-head screws (35) and front panel assy (5) from casing (30). 2 Remove countersunk screws (15) and latch (10) from front panel assy (5). 3 Remove countersunk screw (25) and grip (20) from front panel assy (5). (c) Remove countersunk screws (70) and rail guides (65) from casing (30).
(3)
Ice drawer assy (refer IPC, fig 17B) (a) Removal of ice bin assy (40). 1 Loosen knurled nut (50) and remove ice bin assy (40) from container (30). 2 Remove sieve (45) from ice bin assy (40). 3 Remove knurled nut (50) and hexagonal nut (55) from ice bin assy (40). (b) Removal of front panel assy (5) 1 Remove countersunk screws (35) and front panel assy (5) from container (30). 2 Remove countersunk screws (15) and latch (10) from front panel assy (5). 3 Remove countersunk screws (25) and grip (20) from front panel assy (5). (c) Remove countersunk screws (65), washers (70) and rail guides (60) from casing (30).
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O.
Waste Container Assemblies (1) Waste container assy (refer IPC, fig 18) (a) (b) (2) Remove pan-head rivets (15), clamps (10) and handles (5) from waste container. Remove pan-head screws (25), washers (30), hexagonal nuts (35) and skids (20) from waste container.
Waste container assy (refer IPC, fig 18A) (a) Drill out countersunk rivets (15) and remove clamps (10) and handles (5) from waste container.
P.
Sliding Work Table Assemblies (1) Sliding work table assy (refer IPC, fig 19) (a) (b) (c) (d) (e) Push knob (45) and remove sliding work table (5) from pan (10). Remove countersunk screws (20) and sliders (15) from sliding work table (5). Remove pan-head screw (75) and single revolving catch (70) from stop (25). Remove countersunk screws (90) and stop (25) from pan (10). Removal of retainer assy (30) 1 Remove countersunk screws (90) and retainer assy (30) from pan (10). 2 Remove setscrew (55) and knob (45) from casing (35). 3 Remove spring (50) and retainer (40) from casing (35). (f) (g) Drill out countersunk rivets (85) and remove retainer (80) and teflon (95) from pan (10). Removal of bumper assy (100) 1 Remove countersunk screws (135) and bumper assy (100) from pan (10). 2 Remove countersunk screws (130), cover (110), spring (125), guide (120) and bolt (115) from casing (105). (h) Pull off teflons (60, 65) from pan (10) in case of damage only.
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(2)
Sliding work table assy (refer IPC, fig 19A) (a) (b) (c) (d) (e) Push knob (45) and remove sliding work table (5) from pan (10). Remove countersunk screws (20) and sliders (15) from sliding work table (5). Remove pan-head screw (75) and single revolving catch (70) from stop (25). Remove countersunk screws (95) and stop (25) from pan (10). Removal of retainer assy (30) 1 Remove countersunk screws (95) and retainer assy (30) from pan (10). 2 Remove setscrew (55) and knob (45) from casing (35). 3 Remove spring (50) and retainer (40) from casing (35). (f) (g) (h) Drill out countersunk rivets (90) and remove retainer (85) and shim (80) from plate (100). Remove pan-head rivets (105), plate (100) and teflon (150) from pan (10). Removal of bumper assy (110) 1 Remove countersunk screws (145) and bumper assy (110) from pan (10). 2 Remove countersunk screws (140), cover (120), spring (135), guide (130) and bolt (125) from casing (115). (i) Pull off shims (60, 65) from pan (10) in case of damage only.
(3)
Sliding work table assy (refer IPC, fig 19B) (a) (b) (c) (d) (e) Push knob (45) and remove sliding work table (5) from pan (10). Remove countersunk screws (20) and sliders (15) from sliding work table (5). Remove pan-head screw (75) and single revolving catch (70) from stop (25). Remove countersunk screws (95) and stop (25) from pan (10). Removal of retainer assy (30) 1 Remove countersunk screws (95) and retainer assy (30) from pan (10). 2 Remove setscrew (55) and knob (45) from casing (35). 3 Remove spring (50) and retainer (40) from casing (35).
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(f) (g) (h)
Drill out countersunk rivets (90) and remove retainer (85) and shim (80) from extrusion (100). Remove pan-head rivets (105), plate (100) and teflon (150) from pan (10). Removal of bumper assy (110) 1 Remove countersunk screws (145) and bumper assy (110) from pan (10). 2 Remove countersunk screws (140), cover (120), spring (135), guide (130) and bolt (125) from casing (115).
(i) Q.
Pull off shims (60, 65) from pan (10) in case of damage only.
Folding Bottom Assy (Refer IPC, Fig 20) (1) (2) Remove pan-head screws (10) and hinge (5) from folding bottom. Remove countersunk screws (25), sliding latch (15) and latch (20) from folding bottom.
R.
Disengaging Installation Assy (Refer IPC, Fig 22) (1) Removal of handle assy (-70) (a) (b) (c) (2) Remove countersunk screw (100), threaded bushing (110) and handle assy (-70) from sliding strip (45). Remove bolt (85), adapter sleeve (90), spring (95), and handle (75) from bracket (80). Pull off sealing tape (105) from bracket (80) in case of damage only.
Removal of disengaging device assy (-5) (a) (b) (c) (d) Remove expander cord (50) from mounting plate (10) and sliding strip (45). Drill out countersunk rivets (25) and remove guide (20) from mounting plate (10). Remove sliding strip (45) from guides (15). Drill out countersunk rivets (25) and remove guides (15) from mounting plate (10).
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(e) (f) (g) S.
Drill out countersunk rivets (65) and remove sledge (35) from mounting plate (10). Remove countersunk screw (60) and roll (55) from mounting plate (10). Pull off profile (40) from mounting plate (10) in case of damage only.
Hot Cup Retainer Assy (Refer IPC, Fig 23) (1) Removal of securing rope assy (-60) (a) (2) Remove countersunk screws (85), support (65), clamp (70), spring (75) and rope (80) from plug plate (5).
Removal of retainer assy (35) (a) (b) Remove countersunk screws (45), clamp (15), retainer assy (35), bearings (10) and bolt (25) with spring (30) from plug plate (5). Remove knob (40) from retainer assy (35).
(3) (4) T.
Remove countersunk screws (50) and fastener (55) from plug plate (5). Remove countersunk screws (50) and cap (20) from plug plate (5).
Upper Attachment Assemblies (1) Upper attachment assy (refer IPC, fig 24) (a) (b) (2) Remove countersunk screws (30), hexagonal nuts (45), washers (40) and rod (15) from connecting plates (20, 25). Remove countersunk screws (35), hexagonal nuts (45), washers (40) and connecting plates (20, 25) from rods (5, 10).
Upper attachment assy (refer IPC, fig 24A) (a) (b) (c) Remove pan-head screws (85), washers (90) and securing ropes (80) from connecting plates (20, 30). Remove countersunk screws (45), hexagonal nuts (50), washers (55), spacers (35) and rods (5) from connecting plates (20, 25, 30). Remove countersunk screws (40), hexagonal nuts (50), washers (55) and connecting plates (20, 25, 30) from rods (10, 15).
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(3)
Upper attachment assy (refer IPC, fig 24B) (a) (b) Remove countersunk screws (40), hexagonal nuts (50), washers (55), spacers (35) and rods (5) from connecting plates (20, 25, 30). Remove countersunk screws (45), hexagonal nuts (50), washers (55) and connecting plates (20, 25, 30) from rods (10, 15).
U.
Sliding Coat Rod Assy (Refer IPC, Fig 25) (1) (2) Remove countersunk screws (20) and stops (15) from guides (10). Remove bolts (25), washers (35) and rolls (30) from frame (5).
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25-05-04
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C L E A N I N G
1.
GENERAL NOTE: For the cleaning procedure of the subcomponents refer to the manufacturer's manuals. A. Thorough cleaning is essential after every flight to meet public health requirements and to ensure satisfactory operation. Thorough cleaning is also an essential prelude to inspection to determine the existence, extent and exact location of defects. Clean especially all recessed parts of the galley units. Deposits of food, spilled liquids, etc., are quite likely to be missed in nooks and crevices and thus allowed to build up and act as cultures for bacteria and mold spores. Therefore, thorough cleaning and sterilization is also extremely important during maintenance to prevent possible food contamination. Cleaning is also an extremely important overhaul function for alclad parts that are exposed to repeated wear, minor nicks, scratches and acids in the form of liquid or vapors. Fruit juices, certain spices and many food products prepared in the galley will attack and corrode alclad once the outer layer of aluminum has been penetrated. These liquids or vapors can seep into nicks and scratches and corrode the material between the outer layers of aluminum, and thus not be readily detectable during the early stages of corrosion. Therefore, thorough cleaning and neutralizing of these acids is necessary to stop corrosion and prevent structural failure.
B.
C.
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D.
The following table lists recommended agents for cleaning the galley units after use. NOTE: Equivalent substitutes may be used for listed items. Substitutes should have the following characteristics: harmless to ferrous metals, aluminum, etc. no residual odor no irritating fumes or vapors nonabrasive ITEM (1) (2) Cleaning agent Cleaning agent IDENTIFICATION AJAX 2000 or 2002 respectively IDEAL FLUESSIG (for decorative material, painted and aluminum surfaces) Application: 95 parts water 5 parts IDEAL FLUESSIG LEONTI SCHEUERPULVER SOURCE COMMERCIALLY AVAILABLE KERTECHEMIE THEODOR KERTESS + CO AN DER WEIDE 13 30173 HANNOVER GERMANY
(3)
Scouring powder
(4)
Polishing cleaner
RIVONIT EDELSTAHLPFLEGER
(5)
Liquid disinfectant
LYSOL
AUGUST LUHN + CO. AG SCHWARZBACH 91-107 42277 WUPPERTAL GERMANY HENKEL UND CIE GMBH HENKELSTR. 67 40589 DUESSELDORF GERMANY COMMERCIALLY AVAILABLE COMMERCIALLY AVAILABLE BREMIN MINERALOEL GMBH & CO KG POSTFACH 45403 MUELHEIM AN DER RUHR GERMANY
(6) (7)
Disinfectant spray Cleaning agent
LYSOL SPRAY FRAGOL CORREX 36 STBG (for hard coated worktops)
CLEANING MATERIALS FIGURE 401
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E.
The following agents are used for cleaning the galley units and/or dismantled parts in the workshop during/after overhaul:
ITEM (1) Aliphatic Naphtha
IDENTIFICATION Federal Specification TT-N95 Military Specification MIL-C38334 LYSOL
SOURCE ANY GOVERNMENT APPROVED SOURCE ANY GOVERNMENT APPROVED SOURCE COMMERCIALLY AVAILABLE ANY GOVERNMENT APPROVED SOURCE COMMERCIALLY AVAILABLE ANY GOVERNMENT APPROVED SOURCE
(2)
Corrosion removing compound Liquid disinfectant
(3)
(4)
Methyl-Ethyl-Ketone (MEK) Disinfectant
Federal Specification TT-M261 LYSOL SPRAY spray Military Specification MIL-T27602
(5)
(6)
Trichlorethylene
CLEANING MATERIALS FIGURE 402
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2.
DETAILED CLEANING INSTRUCTIONS A. Galley Assembly CAUTION: AVOID PENETRATION OF CLEANING AGENT INTO DAMAGED HONEYCOMB OR BASE STRUCTURE TO PREVENT CORROSION. B. Cleaning of Dismantled Parts Component parts should be cleaned by means of compressed air, brush, cloth or sponge. Sheet metal parts should be cleaned with the aid of a cleaning agent e.g. AJAX 2000 or 2002 respectively (refer to fig 401) using a cloth or sponge to wipe clean. C. Cleaning Procedure for Galley Cavity or Exterior Surface (1) Using a cloth or sponge, apply the cleaning agent (solution of water and AJAX 2000, or equivalent) according to the manufacturer's instructions and rub the surface clean, rinse and wipe dry. In case of obstinate contamination apply LEONTI (refer to fig 401) scouring powder to wet cloth, rub the surface, rinse well and dry. (2) For protection of the exterior surface, polishing cleaner such as "RIVONIT EDELSTAHLPFLEGER" (refer to fig 401) should be used. (a) Application Apply polishing cleaner with a dry cloth, apply directly to dry surface and polish. D. Removal of Corrosion (1) Neutralize any signs of corrosion using a cloth saturated in a liquid solution of 50 percent distilled water and 50 percent corrosion removing compound. After neutralizing corrosion, flush area thoroughly with clean, warm water and dry with filtered, compressed air. Mark each area suspected of corrosion and clean in this manner for inspection and preventive treatment. (2) Disinfect all food storage areas by spraying with disinfectant spray.
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E.
Structure Assemblies CAUTION: MANY PARTS OF THE STRUCTURE ASSEMBLY ARE ALCLAD ALUMINUM. BE VERY CAREFUL NOT TO SCRATCH FINISH WHEN SCRAPING. (1) Remove any crusted and stubborn deposits of food and residue by scraping off. After most of the deposit has been removed, wash away the remaining residue as specified in paragraph 2.C. WARNING: USE METHYL-ETHYL-KETONE (MEK) IN A WELL VENTILATED AREA. AVOID PROLONGED INHALATION OF FUMES AND CONTACT WITH SKIN. KEEP MEK AWAY FROM NAKED FLAME. (2) (3) (4) (5) Remove grease or oil deposits by washing with a cloth saturated in MEK (refer to fig 402). Neutralize any signs of corrosion as specified in paragraph 2.D. Disinfect all food storage areas and countertop surfaces by spraying with disinfectant spray (refer to fig 402). To clean the hardcoated worktops use FRAGOL CORREX 36 STBG (refer to fig 401).
F.
Electrical Installation CAUTION: DEENERGIZE POWER WHEN WORKING IN COMPARTMENTS WITH ELECTRICAL INSTALLATION. WARNING: ALIPHATIC NAPHTHA IS FLAMMABLE. USE NAPHTHA ONLY IN A WELL VENTILATED AREA, REMOVED FROM VICINITY OF NAKED FLAME OR ELEVATED TEMPERATURES. AVOID PROLONGED OR REPEATED CONTACT WITH SKIN OR INHALATION OF TOXIC SOLVENT VAPORS. OBEY STANDARD SAFETY PRECAUTIONS FOR HANDLING FLAMMABLE MATERIALS. (1) (2) (3) (4) Lightly brush all accessible electrical parts and wiring with a soft nonmetallic brush. Use dry, filtered air at moderate pressure of 1.72 bar (25 psig) maximum to blow loosened dust and dirt from all parts. Clean all accessible areas using a clean, lintfree cloth dampened with trichloroethylene or equivalent. Allow parts to dry thoroughly after using cleaner. Clean surfaces of electrical units with a clean, lintfree cloth or soft bristle brush moistened in aliphatic naphtha and allow to air dry.
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G.
Water Installation (1) Flush entire installation system with a solution of 5 tablespoons of liquid disinfectant (Lysol, refer to fig 401 or 402) or equivalent, to each gallon of distilled water. Flush entire system with fresh drinking water a minimum of five times. Use clean, dry compressed air at 1.72 bar (25 psig) to blow out and dry parts. Close valves and spigots. Steam oven plumbing system NOTE: It is recommended to drain the steam oven plumbing system in case the aircraft is on ground for a longer period, e.g. checks and overhaul. (a) (b) (c) (d) (e) (f) (g) (h) Turn off the water shut off valve. Remove the steam oven by loosening both fasteners. Retain screws and washers for later reinstallation. Loosen the clamp of the drain hose, attached to the aft wall and place the end into a suitable liquid collecting device, e.g. bucket. Open the drain valve and drain the system completely. Close the drain valve. Fasten the drain hose back on to the aft wall. Re-install the oven. Turn on the water shut off valve.
(2) (3) (4)
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C H E C K
1.
GENERAL A. Perform all checks according to the intervals shown in figure 501. Record all damages detected in order to retrace the frequency and in some cases the reason and/or source. All damages detected must be repaired immediately.
(1) (2) (3) (4) (5) (6) (7) C.
Damage Unobjectionable attachment Corrosion and surface protection Wear Unobjectionable sealing Leakage of water installation Attachment of electrical wires and components
Use a strong light and preferably some means of magnification. Use an inspection mirror in order to examine all exposed surfaces. Use only tools being in good condition and of appropriate size. All repairs must be performed by skilled personnel, who, if no physical values are available, can still judge the condition. Damages which are unmistakably traceable to material or manufacturing errors must be reported to the galley manufacturer immediately. Inspection and the following maintenance or overhaul must be performed according to the requirements in figure 501.
D. E.
F.
G.
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MAXIMUM FLIGHT HOURS (1) MINOR MAINTENANCE 250
MAXIMUM PERIOD
CHECK SYMBOL
UNIT INSTALLED
50 DAYS
YES
(2)
MAINTENANCE
800
5 MONTHS
YES
(3)
MAJOR MAINTENANCE
2500
18 MONTHS
YES
(4)
INTERVAL LAY-OVER
12000
3 YEARS
NO
(5)
OVERHAUL
24000
6 YEARS
NO
CHECK INTERVALS FIGURE 501
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2.
CHECK PROCEDURES CHECK INTERVALS REFER TO FIG 501 A. Structure In General (1) (2) Check structure in general for evidence of scratches, cracks, holes and various damages. Check for damaged or loose decorative material and damaged coating and for other possible surface damages. Check if corrosion is present, especially in damp compartments, milled or metal components. Check trims, protective strips and kick strips for attachment. Check areas that are not easily accessible for cleanliness to prevent corrosion. A A A A B B C C D D E E
(3) (4) (5)
B B B
C C C
D D D
E E E
B.
Lower And Upper Attachment CAUTION: (1) OBJECTIONABLE COMPONENTS MUST BE REPLACED. B C D E
Check lower and upper attachment of galley units for fit and security. If necessary, replace damaged components and take torque values. Make sure there are no vibration markings at lower attaching parts. Check all attachment components for surface corrosion. Inspect carefully condition of sealing at the lower attachment. Check tie rods of upper attachment for easy movement. A
(2) (3) (4)
B B B
C C C
D D D
E E E
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CHECK INTERVALS REFER TO FIG 501 C. Unit Joints (1) D. Check screwed joints for firm seating. B C D E
Screwed And Riveted Connections (1) Check screwed and riveted connections for firm seating. C D E
E.
Revolving Catches (1) Check revolving catches for damage, firm seating and easy operation in the vertical and horizontal position. Check torque values of catch stop in both directions by using a torque screwdriver and adapter of appropriate size. REMARK: Refer to figure 901 for appropriate tools and to figure 801 and 803 for torque values. A B C D E
(2)
F.
Sliding Strips And Bumpers (1) Check sliding strips and bumpers for attachment and wear. REMARK: Bumpers and sliding strips showing wear of 50% must be replaced. A B C D E
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CHECK INTERVALS REFER TO FIG 501 G. Doors And Drawers (1) (2) (3) Check doors and drawers for easy and uniform closure. Check door hinges and latches for attachment. Check hinges for operation and distortion resulting from outside damage. REMARK: If required, lubricate with vaseline oil. (4) (5) Check hinge pins and springs for condition and security. Check door and drawer latches. NOTE: Latch bolt must protrude at least 5 mm over the front of door extrusion. (6) (7) Check strikes for attachment and wear. Check extrusions of doors and door frames for damage or distortion. C C D D E E A B B C C D D E E A A A B B B C C C D D D E E E
H.
Work Tables And Work Counter Tops (1) (2) Check attachment and engagement of sliding work tables. Check all work tables and work counters for flawless sealing and other damage. A A B B C C D D E E
I.
Air Screens And Filter Pads (1) Check attachment, cleanliness and condition of catch. NOTE: Clean contaminated air screen and replace filter pad. A B C D E
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CHECK INTERVALS REFER TO FIG 501 J. Latches And Fasteners (1) Check sliding latches for operation and cleanliness. NOTE: Control spot red/green must be visible. (2) Check latches and fasteners for operation and cleanliness. B C D E C D E
K. L.
Check placards for presence and attachment. Water Installation (1) (2) (3) (4) (5) (6) (7) (8) Check clamps and supports for attachment and damage. Check hoses and tubes for attachment. Check fittings, tube and hose connections for leaks and damage. Check water system with a pressure of 125 psi (8.62 bar) for possible leakage. Check drain line for unobstructed flow. Check faucets and valves for operation. Check hoses and gaskets for signs of aging. Check water filter for cleanliness and quantity of flow. REMARK: Replacement should follow not later than a flow of 5700 liters or 2000 flight hours. A A
B B
C C C
D D D D D D D
E E E E E E E E
B B B
C C C
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CHECK INTERVALS REFER TO FIG 501 M. Electrical System (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Check mechanical function of switches and circuit breakers. Check wires and electrical components for attachment, damage and overheating signs. Check all electrical connections for tightness and contact. Check connections for cleanliness. Check plugs and receptacles for loose, broken and missing pins or contact sockets. Check terminal lugs for firm connection on wire ends. Check connections on terminal boards and ground studs for corrosion. Check sealing and coating of ground studs for damage. Check soldered and crimped connections for security. Check tension relief clamps on plugs and receptacles for security. Check wires and appliances for insulation resistance according to chapter TESTING para. 4. Perform dielectric test according to chapter TESTING para. 4. Check work light lenses, area light lenses, caps and control lamps for cleanliness, damage and presence. Check that all bulbs and fluorescent tubes in work lights, area lights and indicator lights are burning. A B C B B B B B B B B B C C C C C C C C C C D D D D D D D D D D D D D E E E E E E E E E E E E E
(14)
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CHECK INTERVALS REFER TO FIG 501 N. Cooling System (1) (2) (3) (4) Check clamps for attachment and damage. Check air ducts for attachment and damage. Check temperature gauge for operation and damage. Check air flaps for proper operation. B B B C C C C D D D D E E E E
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R E P A I R
U
1.
U
GENERAL
U
A.
U
Repair Materials NOTE: Equivalent substitutes may be used for listed items.
U
DESIGNATION/ SPECIFICATION (1) Primer
PART NUMBER EC1945B/A
(2) Adhesive
EC2216B/A
SOURCE MINNESOTA MINING AND MFG CO ADHESIVES COATINGS AND SEALERS DIV 3 M CENTER ST PAUL MN 55144-1000 E L N N 3861 USA
(3) Adhesive
FASTBOND 10
(4) Sealant (5) Adhesive (6) Adhesive tape (7) Sealant
EC3524B/A EC7838B/A Y4930 RTV102 RTV103 RTV108 RTV109 GENERAL ELECTRIC CO SILICON PRODUCTS HUDSON RIVER RD WATERFORD NY 12188 USA
APPLICATION Primer for adhesive EC2216B/A at metal surfaces. Stainless steel sheet bonded with fiberglass or light alloy. Light alloy sheet bonded with light alloy sheet, structure parts and extrusions. Bonding of inserts. Rebonding of decorative materials. Filling of cut edges of sandwich panels. Bonding of cooled air ducts. Bonding of sliding strips. Sealing of sandwich panels and extrusion joints. Sealing of food contact surfaces.
REPAIR MATERIAL TABLE FIGURE 601 SH 1 OF 3
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DESIGNATION/ SPECIFICATION (8) Sealant
PART NUMBER 3054
(9) Adhesive
222
(10) Sealant
E43
(11) Permanent plastic corrosion Protecting paste (12) Electrical wires
N53622
EN2267-008A
(13) Cleaning and degreasing Agent (14) Corrosion preventative compound (15) Solder
Methyl-EthylKetone (MEK) Acetone MIL-C10382
SOURCE BOSTIK GMBH CHEMISCHE FABRIK GATTENHOEFER WEG 36 61440 OBERURSEL GERMANY LOCH-KLEBETECHNIK ROEMERSTR. 100 - 111 59075 HAMM GERMANY WACKER-CHEMIE GMBH PRINZREGENTENSTRASSE 22 80538 MUENCHEN GERMANY ICI LACKE-FARBEN GMBH DUESSELDORFER STRASSE 102 40721 HILDEN GERMANY NEXAN FRANCE FILOTEX BONNENBROICHERSTR. 2-14 41238 MOENCHENGLADBACH GERMANY ANY GOVERNMENT APPROVED SOURCE ANY GOVERNMENT APPROVED SOURCE ANY GOVERNMENT APPROVED SOURCE ANY GOVERNMENT APPROVED SOURCE
APPLICATION Sealing of sandwich panels and extrusion joints. Sealing of cadmium plated parts. Securing of nuts, screws and bolts.
Sealing of work area.
Wet installation of attaching parts, etc.
For galley wiring.
Manual cleaning and degreasing. Corrosion prevention.
QQS 571, TYPE SN 60 (16) Zinc chromate MIL-P8586 primer
For electrical wires. For clad aluminum.
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DESIGNATION/ SPECIFICATION (17) Abrasive cloth (18) Terminal lugs
PART NUMBER 120 grid or finer PIDGE RING TONGUE TERMINALS LC081-6140
(19) Primer
(20) Sealant
PR1422A
(21) Lacquer
NYCOTE 7-11
SOURCE COMMERCIALLY AVAILABLE AMP DEUTSCHLAND GMBH AMPERESTRASSE 7 - 11 63225 LANGEN GERMANY BASF LACKE UND FARBEN AG VITALISSTR. 198-226 50827 KOELN GERMANY PRODUCTS RESEARCH AND CHEMICAL CORP 5430 SAN FERNANDO RD P O BOX 1800 GLENDALE CA 91209 USA NYCOTE LABORATORIES 12570 RAYMER ST NORTH HOLLYWOOD CA 91605 USA
APPLICATION Sanding and polishing. Refer chapter TESTING AND FAULT ISOLATION. Primer for metalmetal contact surfaces.
Sealing of ground studs after installation.
Coating of ground studs after installation and sealing.
25-05-04
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B.
Except for permissible repairs outlined in the following paragraphs, repair of detail parts and components is neither considered practicable nor reliable during maintenance. For repair refer to repair manual 25-32-03. Parts which do not meet inspection requirements shall be replaced. Certain structural subassemblies are not procurable separately and if damaged, the next higher assembly should be procured. Refer to ILLUSTRATED PARTS CATALOG 25-05-04 for details.
C.
The following parts, if removed during the disassembly procedure, shall be routinely replaced at each overhaul, regardless of apparent condition. (1) (2) (3)
U
All screws, bolts, washers, nuts, bushings, etc. All seals. All bulbs and fluorescent tubes. CAUTION: DO NOT ATTEMPT TO REPAIR BY WELDING THE UNIT STRUCTURE OR COMPONENTS!
U
D.
Repair of minor dents and deformation of structural skins and frames may be accomplished with standard metal repair tools. Rivet replacement may be accomplished at overhaul shop level. Permissible limitations of sizes of drilled-out rivet holes are controlled by standard shop practices used for oversized replacement rivets (refer to repair manual 25-32-03). NOTE: Minimum pitch and edge distances for rivets are determined by original manufacturer and shall be closely observed during repair.
U U
E.
F.
Treat all areas marked for corrosion preventative treatment with corrosion preventative petrolatum (refer to fig 601). For further instructions refer to repair manual 25-32-03.
25-05-04
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2.
U
GALLEY STRUCTURE
U
A.
Except for food contact surfaces, fill all cracks and crevices with EC3524B/A sealant (refer to fig 601). Seal gaps on sandwich panels and extrusion joints with 3054 sealant (refer to fig 601). Seal gaps on and around food contact surfaces with RTV102, RTV103, RTV108 and/or RTV109 sealant (refer to fig 601). If protective coating has been removed for any reason, touch up with two coats of primer and one coat of lacquer, acid resistant lacquer or equivalent (refer to fig 601 for primer and for lacquer). If decorative material has pulled away from structure, rebond using FASTBOND 10 or equivalent (refer to fig 601). Remove any excessive adhesive compound by wiping with a cloth dampened in MEK (refer to fig 601).
B. C.
D.
E.
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3.
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FIBERGLASS SANDWICH STRUCTURE

U
A.
This subject describes repairs to panels of sandwich construction consisting of nomex honeycomb core to which fiberglass skin is bonded on both sides as face plies. Fiberglass sandwich is used in most of the galley unit structures. Damage is defined as any visible change on the surface resulting from deterioration, delamination, erosion, dents, gouges, scratches, punctures and holes. If sandwich panelling has been gouged or otherwise marred and requires edging and/or sealing, proceed as follows: (1) (2) Mask around the repair area allowing 1.5 mm (1/16 inch) gap between tape edge and panel surface. Remove any dirt or residue (cuttings, etc.) by blowing with clean, filtered air and wiping with a cloth dampened in MEK (refer to fig 601) allowing to air dry for 15 minutes. Fill hole with potting compound EC3524B/A or equivalent (refer to fig 601). The potting compound may be applied by any convenient method (trowel, putty knife, caulking gun, etc.) as long as sufficient quantity is deposited to allow for sanding the edges smooth after cure. Excessive uncured potting compound may be removed from panel surface with MEK (refer to fig 601). After curing, sand repaired surface smooth and buff or polish until blended with adjacent areas.
B. C.
D.
(3) (4)
(5)
4.
U
METAL STRUCTURES
U
A.
Stainless Steel Sheets (1) Minor damages (a) (b) Remove minor scratches, stains, etc. using a burnishing tool, utilizing 120 grit or finer abrasive cloth/abrasive coated belt with oil. Blend the repaired area with adjacent surface.
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(c) (2)
Wipe off all oil residue.
Major damages (a) In case of major damages, replacement is necessary.
B.
Clad Aluminum (1) (2) (3) (4) (5) Remove scratches and edge burrs using a burnishing tool. Blend the repaired area with adjacent surface using 320 grit or finer abrasive cloth with oil. Wipe off all oil residue from the aluminum surface. Apply masking tape around scratch to confine area affected to 6.3 mm (1/4 inch) or less in width. Apply zinc chromate primer (refer to fig 601) to affected area. Allow the primer to dry before removing the tape and reinstalling the part.
C.
Electroplated Surface (1) (2) Remove minor scratches, stains and corrosion by light buffing. However, be careful not to penetrate the plating. Replace any part not repairable by light buffing.
5.
U
ELECTRICAL INSTALLATION
U
A.
Defective Wiring (1) (2) Replace wiring found to be defective during inspection. Repair of defective/cracked wires may be accomplished by splicing which depends on the discretion of the electrician.
B.
Soldered Wire Terminations
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(1)
Where wire terminations are soldered, unsolder old wiring and solder new wires in accordance with Military Specification MIL-S-6872, using SN60 solder.
C.
Electrical Components (1) Replace all electrical components which do not pass inspection requirements or are found to be defective during inspection. NOTE: Refer to wiring diagrams for correct wire termination and wire gauge. The last two numbers of the wire number indicate wire gauge.
U U
(2)
Seal ground studs with sealant PR1422A and coat NYCOTE 7-11 after installation (refer to fig 601).
6.
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COOLING SYSTEM
U
A.
General CAUTION:
U U
AFTER ANY OPENING OF THE COOLING SYSTEM, THE FILTER DRIER MUST BE EXCHANGED.
(1)
Lines which are found to be repaired should only be opened in warm condition to avoid coating with moisture. Make sure, that no dirt, dust, moisture or other contaminations can enter the open lines or components. Evaporator plates are made of aluminum alloy and are not easily repaired. Any damaged evaporator plate will require replacement. If tubing or fittings are broken or damaged, replacement is necessary.
(2) (3)
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A S S E M B L Y
1.
GENERAL A. Assembly Materials NOTE: Equivalent substitutes may be used for listed items. DESIGNATION/ SPECIFICATION (1) Primer
PART NUMBER EC1945B/A
(2) Adhesive
EC2216B/A
SOURCE MINNESOTA MINING AND MFG CO ADHESIVES COATINGS AND SEALERS DIV 3 M CENTER ST PAUL MN 55144-1000 E L N N 3861 USA
(3) Adhesive
FASTBOND 10
(4) Sealant (5) Adhesive (6) Adhesive tape (7) Sealant
EC3524B/A EC7838B/A Y4930 RTV102 RTV103 RTV108 RTV109 GENERAL ELECTRIC CO SILICON PRODUCTS HUDSON RIVER RD WATERFORD NY 12188 USA
APPLICATION Primer for adhesive EC2216B/A at metal surfaces. Stainless steel sheet bonded with fiberglass or light alloy. Light alloy sheet bonded with light alloy sheet, structure parts and extrusions. Bonding of inserts. Rebonding of decorative materials. Filling of cut edges of sandwich panels. Bonding of cooled air ducts. Bonding of sliding strips. Sealing of sandwich panels and extrusion joints. Sealing of food contact surfaces.
ASSEMBLY MATERIAL TABLE FIGURE 701 SH 1 OF 3
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DESIGNATION/ SPECIFICATION (8) Sealant
PART NUMBER 3054
(9) Adhesive
222
(10) Sealant
E43
(11) Permanent plastic corrosion Protecting paste (12) Electrical wires
N53622
EN2267-008A
(13) Cleaning and degreasing Agent (14) Corrosion preventative compound (15) Solder
Methyl-EthylKetone (MEK) Acetone MIL-C10382
SOURCE BOSTIK GMBH CHEMISCHE FABRIK GATTENHOEFER WEG 36 61440 OBERURSEL GERMANY LOCH-KLEBETECHNIK ROEMERSTR. 100 - 111 59075 HAMM GERMANY WACKER-CHEMIE GMBH PRINZREGENTENSTRASSE 22 80538 MUENCHEN GERMANY ICI LACKE-FARBEN GMBH DUESSELDORFER STRASSE 102 40721 HILDEN GERMANY NEXAN FRANCE FILOTEX BONNENBROICHERSTR. 2-14 41238 MOENCHENGLADBACH GERMANY ANY GOVERNMENT APPROVED SOURCE ANY GOVERNMENT APPROVED SOURCE ANY GOVERNMENT APPROVED SOURCE ANY GOVERNMENT APPROVED SOURCE COMMERCIALLY AVAILABLE
APPLICATION Sealing of sandwich panels and extrusion joints. Sealing of cadmium plated parts. Securing of nuts, screws and bolts.
Sealing of work area.
Wet installation of attaching parts, etc.
For galley wiring.
Manual cleaning and degreasing. Corrosion prevention.
QQS 571, TYPE SN 60 (16) Zinc chromate MIL-P8586 primer (17) Abrasive 120 grid or cloth finer
For electrical wires. For clad aluminum. Sanding and polishing.
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DESIGNATION/ SPECIFICATION PART NUMBER (18) Terminal lugs PIDGE RING TONGUE TERMINALS (19) Torque screwdriver 2640
SOURCE AMP DEUTSCHLAND GMBH AMPERESTRASSE 7 - 11 63225 LANGEN GERMANY WALTER CARL GMBH UND CO KG POSTFACH 150244 42340 WUPPERTAL GERMANY
APPLICATION Refer chapter TESTING AND FAULT ISOLATION. Taking torque values of revolving catches according to fig 801.
(20) (21) (22) (23)
Adapter No.1 Adapter No.2 Adapter No.3 Primer
5035-02-0085A 5035-02-0085B 5035-02-0085D LC081-6140
(24) Sealant
PR1422A
(25) Lacquer
NYCOTE 7-11
BASF LACKE UND FARBEN AG VITALISSTR. 198-226 50827 KOELN GERMANY PRODUCTS RESEARCH AND CHEMICAL CORP 5430 SAN FERNANDO RD P O BOX 1800 GLENDALE CA 91209 USA NYCOTE LABORATORIES 12570 RAYMER ST NORTH HOLLYWOOD CA 91605 USA
Primer for metalmetal contact surfaces.
Sealing of ground studs after installation.
Coating of ground studs after installation and sealing.
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B.
Assembly of components and installation of the galley units into the airplane must be accomplished by qualified mechanics. All installation work should be done very carefully to avoid any damage to the surfaces of the galley assemblies. Attaching parts, e.g. screws, nuts, bushings, etc., and sealings being slightly damaged must not be used again, but must be replaced. Revolving Catches (1) After installation of revolving catches their torque values must be taken according to figure 801, figure 803 and figure 901.
C.
D.
E.
Water Installation (1) The water installation system should be tested after installation using a test pressure of 125 psi (8.62 bar).
F.
Electrical Installation (1) (2) Make drip loops on wire bundle when installing cables to electrical components (refer to fig 702). Seal ground studs after installation.
DRIP LOOP FIGURE 702
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2.
GALLEY UNIT G1, G2, G3, G4, G5, G6, G7, G4A, RH CLOSET, RH COAT CLOSET AND AFT PARTITION UNIT ASSEMBLY NOTE: For illustrations and item numbers refer ILLUSTRATED PARTS CATALOG 25-05-04. NOTE: For compartment numbers refer chapter DESCRIPTION AND OPERATION.
A.
Door Assemblies (1) Door assy (refer IPC, fig 14) (a) (b) (c) (2) Install sliding strip (30) to door. Install latch (20) to door with countersunk screws (25). Install hinge (5) to door with countersunk screws (10) and washers (15).
Door assy (refer IPC, fig 14A) (a) (b) Install latch (20) to door with countersunk screws (25). Install hinge (5) to door with countersunk screws (10) and washers (15).
(3)
Door assy (refer IPC, fig 14B) (a) (b) Install latch (20) to door with countersunk screws (25). Install hinges (5) and covers (10) to door with countersunk screws (15).
(4)
Door assy (refer IPC, fig 14C) (a) (b) Install latch (15) to door with countersunk screws (20). Install hinge (5) to door with pan-head screws (10).
(5)
Door assy (refer IPC, fig 14D) (a) (b) (c) (d) Install kick strip (25) to door. Install extrusion (50) and shim (55) to door with pan-head screws (60). Install end parts (40) and protecting strip (30) to door with pan-head screws (45). Install filling strip (35) to protecting strip (30).
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(e) (f) (6)
Install latch (15) to door with countersunk screws (20). Install hinge (5) to door with countersunk screws (10).
Door assy (refer IPC, fig 14E) (a) (b) (c) (d) (e) Install kick strip (30), bumpers (55) and shims (60). Install end parts (45) and protecting strip (35) to door with pan-head screws (50). Install filling strip (40) to protecting strip (35). Install latch (15) to door with countersunk screws (25). Install hinge (5) with springs (15) to door with countersunk screws (10).
(7)
Door assy (refer IPC, fig 14F) (a) (b) (c) (d) (e) (f) Install kick strip (30) to door. Install end parts (45) and protecting strip (35) to door with pan-head screws (50). Install filling strip (40) to protecting strip (35). Install bumpers (55, -55A) to door with countersunk screws (60, -60A, 65, -65A). Install latch (20) to door with countersunk screws (25). Install hinges (5) and covers (10) to door with countersunk screws (15).
(8)
Door assy (refer IPC, fig 14G) (a) (b) (c) (d) (e) Install kick strip (30) to door. Install end parts (45) and protecting strip (35) to door with pan-head screws (50). Install filling strip (40) to protecting strip (35). Install latch (20) to door with countersunk screws (25). Install hinges (5) and covers (10) to door with countersunk screws (15).
(9)
Door assy (refer IPC, fig 14H) (a) Install kick strip (45) to door.
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(b) (c) (d) (e) (f) (g) (10)
Install washers (70) to door with countersunk screws (75). Install end parts (60) and protecting strip (50) to door with pan-head screws (65). Install filling strip (55) to protecting strip (50). Install spacers (35), shims (30) and bumpers (25) to door with countersunk screws (40). Install grip (15) to door with countersunk screws (20). Install hinge (5) to door with pan-head screws (10).
Door assy (refer IPC, fig 14J) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Install kick strip (35), bumpers (90), shims (95) and sealing profiles (135) to door. Install latch (25) to door with countersunk screws (30). Install end part (50) and protecting strip (40) to door with pan-head screws (55). Install filling strip (45) to protecting strip (40). Install latch (20) to door with countersunk screws (30). Install extrusion (125) to door with pan-head rivets (130). Install extrusion (100) to extrusion (125) with countersunk rivets (105). Install plates (110, 115) to door with countersunk screws (120). Install hinges (5) and covers (10) to door with countersunk screws (15). Installation of waste flap assy (60) 1 Install hinge (-70) with springs (-75) to waste flap (-65) with countersunk rivets (-80). 2 Install waste flap assy (60) to door with countersunk screws (85).
(11)
Door assy (refer IPC, fig 14K) (a) (b) Install kick strip (35) to door. Install extrusion (70) and teflon (75) to door with pan-head screws (80).
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(c) (d) (e) (f) (g) (12)
Install extrusion (60) to door with pan-head screws (65). Install end parts (50) and protecting strip (40) door with pan-head screws (55). Install filling strip (45) to protecting strip (40). Install latches (20, 25) to door with countersunk screws (30). Install hinges (5) and covers (10) to door with countersunk screws (15).
Door assy (refer IPC, fig 14L) (a) (b) (c) Install plates (20) to door with fasteners (15). Install closing cap (25) to door with countersunk rivets (30). Install hinge (5) to door with pan-head screws (10).
(13)
Door assy (refer IPC, fig 14M) (a) (b) Install latch (20) to door with countersunk screws (25). Install hinge (5) to door with countersunk screws (10) and washers (15).
(14)
Door assy (refer IPC, fig 14N) (a) (b) (c) (d) (e) Install bracket (40) and shim (45) to door with pan-head screws (50) and washers (55). Install grip (30) to door with countersunk screws (35). Install latch (20) to door with countersunk screws (25). Install hinge (-5A) to door with countersunk screws (-10A) and washers (15). Install hinge (5) to door with pan-head screws (10).
(15)
Door assy (refer IPC, fig 14P) (a) (b) Install latches (20, 25) to door with countersunk screws (30). Install hinge (5) to door with countersunk screws (10) and washers (15).
(16)
Door assy (refer IPC, fig 14Q) (a) (b) Install bumpers (30) to door. Install latch (20) to door with countersunk screws (25).
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(c) (17)
Install hinges (5) and covers (10) to door with countersunk screws (15).
Door assy (refer IPC, fig 14R) (a) (b) Install latch (20) to door with countersunk screws (25). Install hinges (5) to door with countersunk screws (10) and washers (15).
(18)
Door assy (refer IPC, fig 14S) (a) (b) (c) (d) (e) Install kick strip (45) to door. Install end parts (35) and protecting strip (25) to door with pan-head screws (40). Install filling strip (30) to protecting strip (25). Install latch (15) to door with countersunk screws (20). Install hinge (5) to door with pan-head screws (10).
(19)
Door assy (refer IPC, fig 14T) (a) (b) Install latch (20) to door with countersunk screws (25). Install hinge (5) with bumper (15) to door with pan-head screws (10).
(20)
Folding door assy (refer IPC, fig 14U) (a) (b) (c) (d) (e) (f) (g) (h) (i) Install kick strips (110, 115) to door. Install end parts (100) and protecting strips (80, 90) to folding door with pan-head screws (105). Install filling strips (85, 95) to protecting strips (80, 90). Install bumpers (60), spacers (70) and shims (65) to folding door with countersunk screws (75). Install washers (50) to folding door with countersunk screws (55). Install grip (40) to folding door with countersunk screws (45). Install extrusions (25) and sealing profile (30) to folding door with countersunk screws (35). Install hinge (10) and shims (15) to folding door with pan-head screws (20). Install hinge (5) to folding door with pan-head screws (20).
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B.
Insulated Door Assemblies (1) Insulated door assy (refer IPC, fig 15) (a) (b) (c) (d) (2) Install sliding strip (30) and shim (40) to insulated door. Install extrusions (50) and sealing profiles (45) to insulated door with pan-head screws (55). Install latch (20) to insulated door with countersunk screws (25). Install hinge (5) with bumpers (30) to insulated door with countersunk screws (10) and washers (15).
Insulated door assy (refer IPC, fig 15A) (a) (b) (c) (d) Install sliding strips (40) and shims (45) to insulated door. Install extrusions (55) and sealing profiles (50) to insulated door with pan-head screws (60). Install latch (30) to insulated door with countersunk screws (35). Install hinges (5, 10) with bolt (15) to insulated door with countersunk screws (20) and washers (25).
(3)
Insulated door assy (refer IPC, fig 15B) (a) (b) (c) (d) (e) (f) (g) (h) Install sliding strip (70) and shim (75) to insulated door. Install end parts (60) and protecting strip (50) to insulated door with panhead screws (65) and washers (100A). Install filling strip (55) to protecting strip (50). Install bumpers (35) and shims (40, 145) to insulated door with countersunk screws (45). Install grip (15) to insulated door with countersunk screws (20). Install washers (25) to insulated door with countersunk screws (30). Install extrusion (105), brush (110) and shim (115) to insulated door with pan-head screws (65A, 120) and washers (100, 150). Install extrusion (125), brush (130) and shim (135) to insulated door with pan-head screws (120) and washers (100, 100A).
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(i) (j) (4)
Install extrusion (90), sealing profile (80) and shim (85) to insulated door with pan-head screws (95) and washers (100, 100A). Install hinge (5) to insulated door with pan-head screws (10).
Insulated door assy (refer IPC, fig 15C) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Install shim (185) and kick strip (205) to insulated door. Install end parts (85) and protecting strip (75) to insulated door with panhead screws (90). Install filling strip (80) to protecting strip (75). Install bumpers (55) and shims (60, 65) to insulated door with countersunk screws (70). Install grip (35) to insulated door with countersunk screws (40). Install washers (45) to d insulated oor with countersunk screws (50). Install extrusions (200), plate (195) and shim (190) to insulated door. Install extrusion (100), sealing profile (95) and shim (105) to insulated door with pan-head screws (110) and washers (115). Install hinges (5, 10, 15, 20) with bolt (25) to insulated door with countersunk screws (30) and washers (210). Installation of brush assy (-155) 1 Install extrusion (160), brush (165) and shims (170, 180) to insulated door with pan-head screws (175). (k) Installation of brush assy (-120) 1 Install extrusion (125), brush (130) and shims (135, 150) to insulated door with pan-head screws (140) and washers (145).
(5)
Insulated folding door assy (refer IPC, fig 15D) (a) (b) (c) Install sliding strips (105, 115), shims (110, 120) and kick strips (200, 205) to insulated folding door. Install extrusions (170, 185), brushes (175, 190) and shims (180, 195) to insulated folding door with pan-head screws (165) and washers (145). Install bumpers (60) and shims (65) to insulated folding door with countersunk screws (70).
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(d) (e) (f) (g) (h) (i) (j) (k) (l) (6)
Install protecting strips (75, 85) and end parts (100) to insulated folding door with pan-head screws (100). Install filling strips (80, 90) to protecting strips (75, 85). Install grips (40) to insulated folding door with countersunk screws (45). Install washers (50) to insulated folding door with countersunk screws (55). Install extrusion (150), brush (155) and shim (160) to insulated folding door with pan-head screws (165) and washers (145). Install extrusion (130), sealing profile (125) and shim (135) to insulated folding door with pan-head screws (140) and washers (145). Install extrusion (25) and sealing profile (30) to d insulated folding oor with countersunk screws (35). Install hinge (10) and shims (15) to insulated folding door with pan-head screws (20). Install hinge (5) to insulated folding door with pan-head screws (20).
Insulated folding door assy (refer IPC, fig 15E) (a) (b) (c) (d) (e) (f) (g) (h) (i) Install sliding strips (105, 115) shims (110, 120) and kick strips (200, 205) to insulated folding door. Install extrusions (170, 185), brushes (175, 190) and shims (180, 195) to insulated folding door with pan-head screws (100) and washers (145). Install shims (65, 165) and bumpers (60) to insulated folding door with countersunk screws (70). Install protecting strips (75, 85) and end parts (95) to insulated folding door with pan-head screws (100) and washers (145). Install filling strips (80, 90) to protecting strips (75, 85). Install grips (40) to insulated folding door with countersunk screws (45). Install washers (50) to insulated folding door with countersunk screws (55). Install extrusion (150), brush (155) and shim (160) to insulated folding door with pan-head screws (100) and washers (145). Install extrusion (130), sealing profile (125) and shim (135) to door with pan-head screws (140) and washers (145).
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(j) (k) (l) (7)
Install shims (15) and hinge (10) to insulated folding door with pan-head screws (20). Install extrusion (25) and sealing profile (30) to insulated folding door with countersunk screws (35). Install hinge (5) to insulated folding door with pan-head screws (20).
Insulated folding door assy (refer IPC, fig 15F) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Install shims (170) and kick strips (180, 185) to insulated folding door. Install protecting strips (70, 80) and end parts (90) to insulated folding door with pan-head screws (95). Install filling strips (75, 85) to protecting strips (70, 80). Install bumpers (45) and shims (50) to insulated folding door with countersunk screws (55). Install grip (35) to insulated folding door with countersunk screws (40). Install washers (60) to insulated folding door with countersunk screws (65). Install extrusion (105), sealing profile (100) and spacer (110) to insulated folding door with countersunk screws (115). Install hinge (10), sealing profile (15) and spacers (20) to insulated folding door with pan-head screws (25). Install hinge (5) to insulated folding door with pan-head screws (30). Installation of brush assy (-150) 1 Install extrusion (155), brushes (160) and shims (165) to insulated folding door with pan-head screws (175) and washers (145). (k) Installation of brush assy (-120) 1 Install extrusion (125), brush (130) and spacer (135) to insulated folding door with pan-head screws (140) and washers (145).
(8)
Insulated folding insulated folding door assy (refer IPC, fig 15G) (a) (b) Install shims (175, 185, 200, 210), plates (190, 205), sealing profiles (195) and kick strips (220, 225) to insulated folding door. Install protecting strips (85) and end parts (95) to insulated folding door with pan-head screws (100).
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(c) (d) (e) (f) (g) (h) (i) (j) (k) (l)
Install filling strips (90) to protecting strips (85). Install bumper (70) and shims (75, 80) to insulated folding door with countersunk screws (155). Install grip (55) to insulated folding door with countersunk screws (60). Install washers (65) to insulated folding door with countersunk screws (50). Install extrusion (110), sealing profile (105) and shim (115) to insulated folding door with pan-head screws (120) and washers (125). Install hinge (30), spacers (215) and shims (115) to insulated folding door with countersunk screws (35). Install extrusion (45) and sealing profile (40) to insulated folding door with countersunk screws (50). Install hinges (5, 10, 15, 20) and bolt (25) to insulated folding door with countersunk screws (230) and washers (235). Install extrusions (160), brushes (165) and shims (170, 180) to insulated folding door with pan-head screws (150) and washers (125). Installation of brush assy (-130) 1 Install extrusion (135), brush (140) and shim (145) to insulated folding door with pan-head screws (150) and washers (125).
C.
Roller Blind Assy (refer IPC, fig 16) (1) Installation of roller blind lock assy (5) (a) (b) (c) (d) (e) Install shell (15) to roller blind lock assy (5) with countersunk screws (20). Install brackets (40) to shell (15)with countersunk screws (55). Install rods (70, 75, 80, 85), spring (90) and sliders (65) to brackets (40, 45, 50) with adapter sleeves (95). Install knobs (25) to sliders (65) with countersunk screws (35) and washers (30). Install cover (105) to roller blind lock assy (5) with pan-head screws (60).
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D.
Drawer Assemblies (1) Ice drawer assy (refer IPC, fig 17) (a) (b) Install rail guides (55) to casing (20) with countersunk screws (60). Installation of front panel assy (5) 1 Install latch (10) to front panel assy (5) with countersunk screws (15). 2 Install front panel assy (5) to casing (20) with pan-head screws (25). (c) (d) (2) Install ice bin (30) to casing (20) with countersunk screw (40), knurled nut (35) and hexagonal nut (45). Install sieve (50) to ice bin (30).
Drawer assy (refer IPC, fig 17A) (a) (b) Install rail guides (65) to casing (30) with countersunk screws (70). Installation of front panel assy (5) 1 Install grip (20) to front panel assy (5) with countersunk screw (25). 2 Install latch (10) to front panel assy (5) with countersunk screws (15). 3 Install front panel assy (5) to casing (30) with pan-head screws (35). (c) Installation of ice bin assy (40). 1 Install ice bin assy (40) to casing (30) with countersunk screw (55), knurled nut (50) and hexagonal nut (60). 2 Install sieve (45) to ice bin assy (40).
(3)
Ice drawer assy (refer IPC, fig 17B) (a) (b) Install rail guides (60) to casing (30) with countersunk screws (65) and washers (70). Installation of front panel assy (5) 1 Install grip (20) to front panel assy (5) with countersunk screws (25). 2 Install latch (10) to front panel assy (5) with countersunk screws (15).
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3 Install front panel assy (5) to container (30) with countersunk screws (35). (c) Installation of ice bin assy (40). 1 Install knurled nut (50) and hexagonal nut (55) to ice bin assy (40). 2 Install sieve (45) to ice bin assy (40). 3 Install ice bin assy (40) to container (30) and secure with knurled nut (50). E. Waste Container Assemblies (1) Waste container assy (refer IPC, fig 18) (a) (b) (2) Install skids (20) to waste container with pan-head screws (25), washers (30) and hexagonal nuts (35). Install handles (5) to waste container with pan-head rivets (15) and clamps (10).
Waste container assy (refer IPC, fig 18A) (a) Install handles (5) to waste container with countersunk rivets (15) and clamps (10).
F.
Sliding Work Table Assemblies (1) Sliding work table assy (refer IPC, fig 19) (a) (b) Install teflons (60, 65) to pan (10). Installation of bumper assy (100) 1 Install cover (110), spring (125), guide (120) and bolt (115) to casing (205) with countersunk screws (130). 2 Install bumper assy (100) to pan (10) with countersunk screws (135). (c) Install retainer (80) and teflon (95) to pan (10) with countersunk rivets (85).
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(d)
Installation of retainer assy (30) 1 Install spring (50) and retainer (40) to casing (35). 2 Install knob (45) to casing (35) setscrew (55). 3 Install retainer assy (30) to pan (10) with countersunk screws (90).
(e) (f) (g) (h) (2)
Install stop (25) to pan (10) with countersunk screws (90). Install single revolving catch (70) to stop (25) with pan-head screw (75). Install sliders (15) to sliding work table (5) with countersunk screws (20). Install sliding work table (5) to pan (10).
Sliding work table assy (refer IPC, fig 19A) (a) (b) (c) (d) Install shims (60, 65) to pan (10). Install plate (100) and teflon (150) to pan (10) with pan-head rivets (105). Install retainer (85) and shim (80) to plate (100) with countersunk rivets (90). Installation of retainer assy (30) 1 Install spring (50) and retainer (40) to casing (35). 2 Install knob (45) to casing (35) with setscrew (55). 3 Install retainer assy (30) to pan (10) with countersunk screws (95). (e) (f) (g) (h) Install stop (25) to pan (10) with countersunk screws (95). Install single revolving catch (70) to stop (25) with pan-head screw (75). Install sliders (15) to sliding work table (5) with countersunk screws (20). Install sliding work table (5) to pan (10).
(3)
Sliding work table assy (refer IPC, fig 19B) (a) (b) Install shims (60, 65) to pan (10). Installation of bumper assy (110) 1 Install cover (120), spring (135), guide (130) and bolt (125) to casing (115) with countersunk screws (140).
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2 Install bumper assy (110) to pan (10) with countersunk screws (145). (c) (d) (e) Install plate (100) and teflon (150) to pan (10) with pan-head rivets (105). Install retainer (85) and shim (80) to extrusion (100) with countersunk rivets (90). Installation of retainer assy (30) 1 Install spring (50) and retainer (40) to casing (35). 2 Install knob (45) to casing (35) with setscrew (55). 3 Install retainer assy (30) to pan (10) with countersunk screws (95). (f) (g) (h) (i) G. Install stop (25) to pan (10) with countersunk screws (95). Install single revolving catch (70) to stop (25) with pan-head screw (75). Install sliders (15) to sliding work table (5) with countersunk screws (20). Install sliding work table (5) to pan (10) with knob (45).
Folding Bottom Assy (Refer IPC, Fig 20) (1) (2) Install sliding latch (15) and latch (20) to folding bottom with countersunk screws (25). Install hinge (5) to folding bottom with pan-head screws (10).
H.
Disengaging Installation Assy (Refer IPC, Fig 22) (1) Installation of disengaging device assy (-5) (a) (b) (c) (d) (e) (f) Install profile (40) to mounting plate (10). Install roll (55) to mounting plate (10) with countersunk screw (60). Install sledge (35) to mounting plate (10) with countersunk rivets (65). Install guides (15) to mounting plate (10) with countersunk rivets (25). Install sliding strip (45) to guides (15). Install guide (20) to mounting plate (10) with countersunk rivets (25).
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(g) (2)
Install expander cord (50) to mounting plate (10) and sliding strip (45).
Installation of handle assy (-70) (a) (b) (c) Install sealing tape (105) to bracket (80). Install adapter sleeve (90), spring (95) and handle (75) to bracket (80) with bolt (85). Install handle assy (-70) to sliding strip (45) with countersunk screw (100) and threaded bushing (110).
I.
Hot Cup Retainer Assy (Refer IPC, Fig 23) (1) (2) (3) Install cap (20) to plug plate (5) with countersunk screws (50). Install fastener (55) to plug plate (5) with countersunk screws (50). Installation of retainer assy (35) (a) (b) (4) Install knob (40) to retainer assy (35). Install retainer assy (35), bearings (10) and bolt (25) with spring (30) to plug plate (5) with countersunk screws (45)and clamp (15),
Installation of securing rope assy (-60) (a) Install support (65), spring (75) and rope (80) to plug plate (5) with countersunk screws (85) and clamp (70).
J.
Upper Attachment Assemblies (1) Upper attachment assy (refer IPC, fig 24) (a) (b) (2) Install connecting plates (20, 25) to rods (5, 10) with countersunk screws (35), washers (40) and hexagonal nuts (45) Install rod (15) to connecting plates (20, 25) with countersunk screws (30), washers (40) and hexagonal nuts (45).
Upper attachment assy (refer IPC, fig 24A) (a) Install connecting plates (20, 25, 30) to rods (10, 15) with countersunk screws (40), washers (55) and hexagonal nuts (50).
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(b) (3)
Install rods (5) to connecting plates (20, 25, 30) with countersunk screws (45), washers (55), spacers (35) and hexagonal nuts (50).
Upper attachment assy (refer IPC, fig 24B) (a) (b) (c) Install connecting plates (20, 25, 30) to rods (10, 15) with countersunk screws (45), washers (55) and hexagonal nuts (50). Install rods (5) to connecting plates (20, 25, 30) with countersunk screws (40), washers (55), spacers (35) and hexagonal nuts (50). Install securing ropes (80) to connecting plates (20, 30) with pan-head screws (85) and washers (90).
K.
Sliding Coat Rod Assy (Refer IPC, Fig 25) (1) (2) Install rolls (30) to frame (5) with bolts (25) and washers (35). Install stops (15) to guides (10) with countersunk screws (20).
L.
Electrical Systems Unit G1, G2, G3, G4, G5, G6, G7, G4A, RH Closet, Door 2, AFT Partition, G3/G4 And G6/G7 (1) Electrical system - Unit G1 (refer IPC, fig 8) (a) Install timer (195), knob (200), fasten tap (205), timer bracket (210), spacer (215), casing (220), sockets (230, 235, 240), cable bracket (245), mounting brackets (300, 305, 310), console (315) and ground stud brackets (320, 325, 330, 335). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle washers (-295), distance sleeves (-275, -280), conduits (-590, -600, -635, -640, -645), sleeves (-605, -610, -615, -620, -625, -630), soldering sleeve (-595) with clamps (-285, -290). 2 Connect wires to ground stud assy (540) a Install wires with hexagonal screw (545) lock washer (550) and washers (555, 560).
(b)
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3 Connect wires to ground stud assemblies (340, 375, 410, 440, 480, 510, 565) a Install hexagonal screws (345, 380, 485), countersunk screw (445), pan-head screw (415) and setscrew (570) with lock washers (350, 385, 490, 520), washers (355, 390, 420, 450, 455, 495, 525) and hexagonal nuts (360, 395, 460, 500, 580). b Install wires to hexagonal screws (345, 380, 485, 515), pan-head screw (415), countersunk screw (445) and setscrew (570) with lock washers (350, 385, 435, 470), washers (365, 400, 425, 465, 495, 525, 585) and hexagonal nuts (370, 405, 435, 475, 505, 535, 575). (c) Electrical components 1 Install indicator light (85), bulb (90), work light (155) and dummy receptacle (150). 2 Install plugs (115, 120, 125, 130, 135) and receptacles (140, 145, 190) with lock screw (185) and clamps (250, 255, 260, 265). 3 Install terminal board (100), terminal bus (110), cover (105, 225) and to control module assy (160) with grommet nut (270). 4 Install circuit breakers (45, 50, 55, 60, 65, 70), toggle switches (75, 80), indicator lights (85) and bulbs (90) to control panel (10). 5 Connect wires to electrical components. (d) Installation of control panel assy (-5) and control module assy (160) 1 Install adhesive tapes (180) to control module assy (160). 2 Install sliding strip (165) to control module assy (160) with pan-head screws (170) and washers (175). 3 Install handles (20) and control panel (10) to control module assy (160) with allen screws (25), lock washers (30) and washers (35). 4 Connect control panel assy (-5) to control module assy (160). 5 Install fasteners (15) to control panel (10). 6 Connect control module assy (160) to electrical system. 7 Install control module assy (160) and secure with fasteners (15). (e) Check electrical system per chapter CHECK.
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(2)
Electrical system - Unit G2 (refer IPC, fig 8A) (a) (b) Install mounting brackets (160), mounting plate (155) and ground stud brackets (170, 175). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle (515) with terminal lug (-450), distance sleeves (-425, -430), conduits (-455, -460, -465, -470, -475), sleeves (-480, -485, -490) with washers (-445) and clamps (-435, -440). 2 Connect wires to ground stud assy (375) a Install wires with hexagonal screw (380), lock washer (385) and washers (390, 395). 3 Connect wires to ground stud assemblies (215, 250, 285, 315, 345, 400) a Install hexagonal screws (220, 255, 320, 350), pan-head screw (290) and setscrew (405) with lock washers (225, 260, 325, 355), washers (230, 265, 295, 330, 360, 420) and hexagonal nuts (235, 270, 335, 365, 415). b Install wires to hexagonal screws (220, 255, 320, 350), pan-head screw (290) and setscrew (405) with lock washers (225, 260, 305), washers (240, 275, 300, 330, 360, 420) and hexagonal nuts (245, 280, 310, 340, 370, 410). (c) Electrical components 1 Install terminal board (115), cover (120) and dummy receptacle (110). 2 Install transformer (180) and plugs (95, 100, 105) with clamps (140, 145, 150). 3 Install terminal bus (135) and terminal board (125) to control module assy (185). 4 Install circuit breakers (45, 50, 55, 60), toggle switches (65), indicator lights (70, 75, 80) and bulbs (85, 90) to control panel (10). 5 Connect wires to electrical components. (d) Installation of control panel assy (-5) and control module assy (185) 1 Install adhesive tape (-205) to control module assy (185).
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2 Install sliding strip (190) to control module assy (185) with pan-head screws (195) and washers (200). 3 Install handles (20) and control panel (10) to control module assy (185) allen screws (25), lock washers (30) and washers (35). 4 Connect control panel assy (10) to control module assy (185). 5 Install fasteners (15) to control panel (10). 6 Connect control module assy (185) to electrical system. 7 Install cover (210) to control module assy (185). 8 Install control module assy (185) and secure with fasteners (15). (e) (3) Check electrical system per chapter CHECK.
Electrical system - Unit G3 (refer IPC, fig 8B) (a) (b) Install ground stud bracket (35). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle with distance sleeves (-5, -10, -15) with washers (-30) and clamps (-20, -25). 2 Connect wires to ground stud assy (40) a Install wires with hexagonal screw (45), lock washer (50) and washers (55, 60). 3 Connect wires to ground stud assemblies (65, 100) a Install hexagonal screws (70, 105) with lock washers (75, 110), washers (80, 115) and hexagonal nuts (85, 120). b Install wires to hexagonal screws (70, 105) with lock washers (75), washers (90, 115) and hexagonal nuts (95, 125). (c) Check electrical system per chapter CHECK.
(4)
Electrical system - Unit G4 (refer IPC, fig 8C) (a) Install mounting brackets (250, 260, 265), bracket (255, 285), ground stud brackets (270, 275, 280) and cable bracket (290).
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(b)
Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle (585), rail (-310), terminal lug (-625), sockets (-630, -635), distance sleeves (-640, -645, -650), conduits (-670, -675, -680, -685, -690, -695) and sleeves (-700, -705, -710, -715, -720, -725) with washers (-665), end clamp (-315) and clamps (-655, -660). 2 Connect wires to ground stud assy (515, 565) a Install wires with hexagonal screw (520, 570) lock washer (525, 575) and washers (535, 580). 3 Connect wires to ground stud assemblies (325, 360, 395, 425, 455, 485, 540) a Install hexagonal screws (330, 365, 430, 460, 490), pan-head screw (400) and setscrew (545) with lock washers (335, 370, 465, 495), washers (340, 375, 405, 435, 470, 500, 560) and hexagonal nuts (345, 380, 475, 505, 555). b Install wires to hexagonal screws (330, 365, 430, 460, 490), pan-head screw (400) and setscrew (545) with lock washers (335, 370, 415, 445), washers (350, 385, 410, 440, 470, 500, 560) and hexagonal nuts (355, 390, 420, 450, 480, 510, 550).
(c)
Electrical components 1 Install work light (130), terminal board (190, 195), cover (195), terminal block (615, 620) and console (320). 2 Install plugs (135, 140, 145, 150, 155), receptacles (160, 165, 170, 175, 180) and transformer (185) with clamps (590, 595, 600, 605) and grommet nut (610). 3 Install terminal board (200), terminal bus (210, 215) and covers (100, 205) to control module assy (220). 4 Install circuit breakers (45, 50, 55, 60, 65, 70, 75), toggle switches (80, 85), knob (95), rotary switch (90), indicator lights (105, 110, 115) and bulbs (120, 125) to control panel (220). 5 Installation of plug support assy (295) a Install cover (-300) to plug support assy with pan-head screws (-305). b Install plug support assy (295) with pan-head screws (135, fig 6A) and washers (285, fig 6A).
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6 Connect wires to electrical components. (d) Installation of control panel assy (-5) and control module assy (220) 1 Install adhesive tapes (-240) to control module assy (220). 2 Install sliding strip (225) to control module assy (220) with pan-head screws (230) and washers (235). 3 Install handles (20) and control panel (10) to control module assy (220) with allen screws (25), lock washers (30) and washers (35). 4 Connect control panel assy (-5) to control module assy (220). 5 Install fasteners (15) to control panel (10). 6 Connect control module assy (220) to electrical system. 7 Install cover (245) to control module assy (220). 8 Install control module assy (220) and secure with fasteners (15). (e) (5) Check electrical system per chapter CHECK.
Electrical system - Unit G5 (refer IPC, fig 8D) (a) (b) Install ground stud brackets (5). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle, covers (-190, -195, -200), distance sleeves (-205, -210, -215) and conduits (-235, -240) with washers (-230) and clamps (-220, -225). 2 Connect wires to ground stud assy (110) a Install wires with hexagonal screw (115) lock washer (120) and washers (125, 130). 3 Connect wires to ground stud assemblies (10, 45, 80, 135, 160) a Install hexagonal screws (15, 50, 85), countersunk screw (165) and setscrew (140) with lock washers (20, 55, 90, 175), washers (25, 60, 95, 155, 170) and hexagonal nuts (30, 65, 100, 150, 180).
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b Install wires to hexagonal screws (15, 50, 85) and countersunk screw (165) with lock washers (20, 55, 175), washers (35, 70, 95, 155, 170), knurled nut (185) and hexagonal nuts (40, 75, 105, 145). (c) (6) Check electrical system per chapter CHECK.
Electrical system - Unit G6 (refer IPC, fig 8E) (a) Install mounting brackets (275, 280, 285, 300, 305, 310), ground stud brackets (315, 320, 325, 330), rail (645) and cable bracket (660) with end clamp (650). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle, wire shield (-620), spacers (-745), sockets (-695, -700), terminal lug (-690), distance sleeves (-715, -720, -725), conduits (-750, -755, -760, -765, -770, -775, -780), sleeves (-785, -790, -795, -800, -805, -810), heat tapes (590, 595), soldering sleeves (-705), fasten tap (-610), pin (-710) with washers (-740) and clamps (-730, -735). 2 Connect wires to ground stud assy (540) a Install hexagonal screw (545) and wires with lock washer (550) and washers (555, 560). 3 Connect wires to ground stud assemblies (350, 385, 420, 450, 480, 510, 565) a Install hexagonal screws (355, 390, 425, 485, 515), pan-head screw (455) and setscrew (570) with lock washers (360, 395, 490, 520), washers (365, 400, 430, 460, 495, 525, 585) and hexagonal nuts (370, 405, 500, 530, 580). b Install wires to hexagonal screws (355, 390, 425, 485, 515), pan-head screw (455) and setscrew (570) with lock washers (360, 395, 440, 470), washers (375, 410, 435, 465, 495, 525, 585) and hexagonal nuts (380, 415, 445, 475, 505, 535, 575). (c) Electrical components 1 Install work light (165), timer bracket (290), consoles (295), timer (600), knob (605), casing (615), terminal block (640) and protecting cover (635). 2 Install plugs (170, 175, 180, 185, 190, 195, 200), receptacles (205, 210, 215, 220, 225, 230), transformer (235), thermostat (240), spring latch
(b)
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(625) and backshells (680) with clamps (665, 670, 675, 685) and grommet nut (655) 3 Install terminal board (125, 140) terminal busses (135, 150) and covers (130, 145, 270) to control module assy (245). 4 Install circuit breakers (45, 50, 55, 60, 65, 70), toggle switches (75, 80, 85), indicator lights (90, 95, 110), bulbs (105, 110), miniature fuse (120), fuse holder (115), resistor (155) and holder (160) to control panel (245). 5 Installation of plug support assy (335) a Install cover (-340) to plug support assy with pan-head screws (-345). b Install plug support assy (335) with pan-head screws (145, fig 6B) and washers (150, fig 6B). 6 Connect wires to electrical components. (d) Installation of control panel assy (-5) and control module assy (245) 1 Install adhesive tapes (-265) to control module assy (245). 2 Install sliding strip (250) to control module assy (245) with pan-head screws (255) and washers (260). 3 Install handles (20) and control panel (10) to control module assy (245) with allen screws (25), lock washers (30) and washers (35). 4 Connect control panel assy (10) to control module assy (245). 5 Install fasteners (15) to control panel (10). 6 Connect control module assy (245) to electrical system. 7 Install cover (270) to control module assy (245). 8 Install control module assy (245) and secure with fasteners (15). (e) (7) Check electrical system per chapter CHECK.
Electrical system - Unit G7 (refer IPC, fig 8F) (a) Install thermostat (250), mounting brackets (260, 265, 270, 275, 285, 290), mounting plate (280), ground stud brackets (295, 300, 305, 310, -315), fasten tap (510), protecting cover (515) and rail (530) with grommet nut (540), end clamp (535) and cable bracket (545).
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(b)
Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle, wire shields (-705, -710), spacers (-610), sockets (-625, -630, -635), terminal lug (-620), distance sleeves (-580, -585, 590), conduits (-640, -645, -650, -655, -660, -665, -670), sleeves (-675, -680, -685, -690, -695, -700), heat tape (255), soldering sleeves (-575), pins (-615) with washers (-605) and clamps (-595, -600). 2 Connect wires to ground stud assy (485) a Install hexagonal screw (490) and wires with lock washer (495) and washers (500, 505). 3 Connect wires to ground stud assemblies (325, 360, 395, 425, 455) a Install hexagonal screws (330, 365, 430, 460) and pan-head screw (400) with lock washers (335, 370, 435, 465), washers (340, 375, 405, 440, 470) and hexagonal nuts (345, 380, 445, 475). b Install wires to hexagonal screws (330, 365, 430, 460) and pan-head screw (400) with lock washers (335, 370, 415), washers (350, 385, 410, 440, 470) and hexagonal nuts (355, 390, 420, 450, 480).
(c)
Electrical components 1 Install terminal block (525), dummy receptacle (200) and console (-320). 2 Install spring latch (520), backshell (565), plugs (155, 160, 165, 170, 175), receptacles (180, 185, 190, 195) and transformer (245) with clamps (550, 555, 560, 570). 3 Install terminal boards (115, 130), terminal busses (125, 140), covers (120, 135), resistor (145) and holder (150) to control module assy (205). 4 Install circuit breakers (45, 50, 55), toggle switches (60, 65), switch (70), rotary switch (75), indicator lights (80, 85, 90), bulbs (95, 100), fuse holder (105), miniature fuse (110), cover (240) and knob (235) to control panel (10). 5 Connect wires to electrical components.
(d)
Installation of control panel assy (-5) and control module assy (205) 1 Install adhesive tapes (-225) to control module assy (205). 2 Install sliding strip (210) to control module assy (205) with pan-head screws (215) and washers (220).
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3 Install handles (20) and control panel (10) to control module assy (205) with allen screws (25), lock washers (30) and washers (35). 4 Connect control panel assy (-5) to control module assy (205). 5 Install fasteners (15) to control panel (10). 6 Connect control module assy (205) to electrical system. 7 Install cover (230) to control module assy (205). 8 Install control module assy (205) and secure with fasteners (15). (e) (8) Check electrical system per chapter CHECK.
Electrical system - Unit G4A (refer IPC, fig 8G) (a) (b) Install bracket (55), cable bracket (15) and ground stud brackets (60). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle (-225), distance sleeves (-20, -25, 30), conduits (-210, -215, -220), pins (-205), jiffy junctions (-195, -200) with washers (-45) and clamps (-35, -40). 2 Connect wires to ground stud assy (170) a Install wires with hexagonal screw (175) lock washer (180) and washers (185, 190). 3 Connect wires to ground stud assemblies (65, 100, 140) a Install hexagonal screws (70, 145) and countersunk screw (105) with lock washers (75, 150), washers (80, 115, 155), spacer (110) and hexagonal nuts (85, 120, 160). b Install wires to hexagonal screws (70, 145) and countersunk screw (105) with lock washers (75, 130), washers (90, 125, 155) and hexagonal nuts (95, 135, 165). (c) Electrical components 1 Install work light (10) and console (50). 2 Connect wires to electrical components. (d) Check electrical system per chapter CHECK.
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(9)
Electrical system RH closet unit (refer IPC, fig 8H) (a) (b) Install bracket (90), mounting plate (95), cable bracket (40) and ground stud brackets (100). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle (-250), distance sleeves (-45, -50, -55), conduits (-75, -80) with washers (-70) and clamps (-60, -65). 2 Connect wires to ground stud assy (180) a Install hexagonal screw (185) and wires with lock washer (190) and washers (195, 200). 3 Connect wires to ground stud assemblies (105, 140, 205) a Install hexagonal screw (110) and countersunk screws (140, 210) with lock washer (115), washers (120, 155, 220), spacers (150, 215) and hexagonal nuts (125, 160, 225). b Install wires to hexagonal screws (110) and countersunk screws (145, 210) with lock washers (115, 170), washers (130, 165, 220) and hexagonal nuts (135, 175, 230). (c) Electrical components 1 Install covers (20, -25, -30, -35), micros switch (5), spot light (15) and console (85). 2 Install plugs (10). 3 Connect wires to electrical components. (d) Check electrical system per chapter CHECK.
(10)
Electrical system Door 2 (refer IPC, fig 8J) (a) (b) Install bracket (50) and ground stud brackets (55). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle (-170), covers (-5, -10, -15), distance sleeves (-20, -25, -30), conduits (-160, -165) with washers (-45) and clamps (-35, -40).
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2 Connect wires to ground stud assy (135) a Install wires with hexagonal screw (140), lock washer (145) and washers (150, 155). 3 Connect wires to ground stud assemblies (60, 95) a Install hexagonal screws (65) and countersunk screw (100) with lock washer (70), washers (75, 110), spacer (105) and hexagonal nuts (80, 115). b Install wires to hexagonal screw (65) and countersunk screw (100) with lock washers (70, 125), washers (85, 120) and hexagonal nuts (90, 130). (c) (11) Check electrical system per chapter CHECK.
Electrical system AFT partition (refer IPC, fig 8K) (a) (b) Install protecting covers (20), cable bracket (35), fasten tap (40), ground stud bracket (75) and contact sockets (-155). Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle, shield wires (-205), distance sleeves (-45, -50, -55), conduits (-170, -175, -180), soldering sleeve (-25) with washers (-70) and clamps (-60, -65). 2 Connect wires to ground stud assemblies (80, 115) a Install hexagonal screws (85, 120) with lock washers (90, 125), washers (95, 130) and hexagonal nuts (100, 135). b Install wires to hexagonal screws (85, 120) with lock washers (90, 125), washers (105, 140) and hexagonal nuts (110, 145). (c) Electrical components 1 Install pins (-160, 165), plugs (5, 10), spring latch (15), backshell (30) and jiffy junction (-150). 2 Connect wires to electrical components. (d) Check electrical system per chapter CHECK.
(12)
Electrical system - Unit G3/G4 (refer IPC, fig 8L) (a) Install sockets (25, 30) and cable bracket (40).
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(b)
Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle, distance sleeves (-60, -65, -70), conduits (-115, -120, -125, -130) with washers (-45) and clamps (-50, -55). 2 Connect wires to ground stud assy (80) a Install hexagonal screws (85) with lock washers (90), washers (95) and hexagonal nuts (100). b Install wire to hexagonal screw (85) with lock washer (90), washer (105) and hexagonal nut (110).
(c)
Electrical components 1 Install fluorescent tubes (35) and ballast units (15). 2 Install backshells (20) and plugs (5, 10). 3 Connect wires to electrical components.
(d) (13)
Check electrical system per chapter CHECK.
Electrical system - Unit G6/G7 (refer IPC, fig 8M) (a) Install fasten tab (70), protecting cover (75), sockets (105), contact sockets (110), bracket (165), mounting brackets (150, 155, 160) and cable bracket (90) with grommet nut (115), Wire bundle NOTE: Make drip loops when installing cables (refer to fig 702). 1 Install wire bundle, terminal lug (-205), distance sleeves (-120, -125, 130), conduits (-215, -220, -225, -230), soldering sleeves (-210) with washer (-80) and clamps (-135, -140). 2 Connect wires to ground stud assy (170) a Install hexagonal screw (175) with lock washer (180), washer (185) and hexagonal nut (190). b Install wire to hexagonal screw (175) with lock washer (180), washer (195) and hexagonal nut (200).
(b)
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(c)
Electrical components 1 Install fluorescent tubes (30, 35), ballast units (60, 65), terminal blocks (40, 45, 50), rail (85) and console (145) with end clamps (55). 2 Install backshells (95), plugs (5, 10) and receptacles (15, 20, 25) with clamps (100). 3 Connect wires to electrical components.
(d) M.
Check electrical system per chapter CHECK.
Water Installation Assemblies Unit G1, G2, G3, G4, G5, G6, G7 And G4A (1) Water installation assy - Unit G3 (refer IPC, fig 9A) (a) (b) Install mounting brackets (5, 10, 15) with countersunk screws (185, 190). Install shut off valve (25), water spigot (65), elbows (85, 90, 95, 100), double nipples (105, 140, 145), T-fittings (110, 115, 120, 125), coupling nipples (130) with gasket (135), sleeves (170, 175), distance sleeves (235), hoses (245, 250) insulating hoses (270, 405) and tubes (320, 325, 350, 355, 360, 365, 370, 375, 380, 385, 390) with hexagonal screws (200, 205), washers (215), lock washers (225) hexagonal nuts (155, 160) and clamps (285, 290, 315). Install drain valve (20), elbow (80), distance sleeves (230), drain stop T-fitting (240), hoses (255, 260, 265), insulating hoses (275, 280), tubes (330, 335, 340, 345) and foams (410, 415) with hexagonal screws (210), washers (220), lock washers (225) and clamps (295, 300, 305, 310), Installation of water filter assy (35) 1 Install reinforcing rings (60) to water filter assy (35). 2 Install gasket (-45) and cartridge (-40) to water filter assy (35). NOTE: After replacing of the water filter cartridge in the water filter it must be strictly mandatory that the vent screw of the filter housing has to be positioned at the highest point, to make sure that cpl. water system will be vented and completely drained. 3 Install filter supports (50, 55) and water filter assy (35) with hexagonal screws (200), lock washers (225) and washers (220).
(c)
(d)
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(e)
Installation of manual operation assy (75) 1 Install mounting angle (10, fig 26). 2 Install bracket (5, fig 26) with countersunk screws (15, fig 26). 3 Install operation label (40, fig 26). 4 Install bowden cable (35, fig 26) to bowden wire (30, fig 26) with bushings (65, fig 26). 5 Install bowden cable (35, fig 26) with bowden wire (30, fig 26). 6 Install and adjusting screw (25, fig 26) to mounting angle (10, fig 26) with hexagonal nuts (70, fig 26) 7 Install end parts (60, fig 26) to bowden cable (35, fig 26). 8 Install bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 9 Install knob (45, fig 26) to bolt (50, fig 26). 10 Connect bowden wire (30, fig 26) and bowden cables (35, 40 fig 26) to bolts (20, fig 26; 50, fig 26) with end parts (60, fig 26) and bushings (65, fig 26).
(f) (g) (2)
Install bonding clips (390, 395, 400). Check water installation assy per chapter CHECK.
Water installation assy - Unit G3 (refer IPC, fig 9B) (a) (b) Install drain stop valve bracket (10) and mounting brackets (5). Install adapter (25), distance sleeves (65), drain stop valve (15), elbows (30, 35), T-fitting (70), insulating hoses (135, 140, 145, 150), insulating foams (155, 160, 165, 170), hoses (120, 125, 130) and tubes (175, 180, 185) with countersunk screws (75, 80), hexagonal screws (85, 90, 95, 100), washers (105), lock washers (110) and clamps (40, 45, 50, 55, 60). Installation of manual operation assy (20) 1 Install mounting angle (10, fig 26). 2 Install bracket (5, fig 26) with countersunk screws (15, fig 26). 3 Install operation label (40, fig 26).
(c)
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4 Install bowden cable (35, fig 26) to bowden wire (30, fig 26) with bushings (65, fig 26). 5 Install bowden cable (35, fig 26) with bowden wire (30, fig 26). 6 Install adjusting screw (25, fig 26) to mounting angle (10, fig 26) with hexagonal nuts (70, fig 26). 7 Install end parts (60, fig 26) to bowden cable (35, fig 26). 8 Install bolts (20, fig 26; 50, fig 26) and springs (55, fig 26. 9 Install knob (45, fig 26) to bolt (50, fig 26). 10 Connect bowden wire (30, fig 26) and bowden cable (35, fig 26) to bolts (20, fig 26; 50, fig 26) with end parts (60, fig 26) and bushings (65, fig 26). (d) (e) (3) Install bonding clip (115). Check water installation assy per chapter CHECK.
Water installation assy - Unit G3 (refer IPC, fig 9B) (a) (b) (c) Install mounting brackets (5, 10) with countersunk screws (45), washers (50) and hexagonal nuts (55). Install reducing part (25), drain valve (15), elbow (30), spacers (40), hoses (60, 65) and tubes (85, 90) with clamps (70, 75, 80). Installation of manual operation assy (20) 1 Install mounting angle (10, fig 26). 2 Install bracket (5, fig 26) with countersunk screws (15, fig 26). 3 Install operation label (40, fig 26). 4 Install bowden cable (35, fig 26) to bowden wire (30, fig 26) with bushings (65, fig 26). 5 Install bowden cable (35, fig 26) with bowden wire (30, fig 26). 6 Install adjusting screw (25, fig 26) to mounting angle (10, fig 26) with hexagonal nuts (70, fig 26). 7 Install end parts (60, fig 26) to bowden cable (35, fig 26). 8 Install bolts (20, fig 26; 50, fig 26) and springs (55, fig 26).
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9 Install knob (45, fig 26) to bolt (50, fig 26). 10 Connect bowden wire (30, fig 26) and bowden cable (35, fig 26) to bolts (20, fig 26; 50, fig 26) with end parts (60, fig 26) and bushings (65, fig 26). (d) (4) Check water installation assy per chapter CHECK.
Water installation assy - Unit G4 (refer IPC, fig 9C) (a) (b) Install mounting brackets (5, 10, 15, 20). Install elbows (85, 90, 95, 100), shut off valve (45), water spigot (55), shell (65), plate (70), coupling nipple (75), gasket (80), double nipples (105, 110, 115), T-fittings (120, 125, 130, 135), socket (140), hoses (200, 205, 210) and tubes (235, 240, 245, 255, 260) with clamps (175), hexagonal nuts (145, 150, 155, 160). Install exhaust valve (50), spacer (165), hoses (215, 220, 225, 230) and tube (265) with clamps (170, 180, 185). Installation of water filter assy (25) 1 Install gasket (30) and cartridge (35) to water filter assy (25). NOTE: After replacing of the water filter cartridge in the water filter it must be strictly mandatory that the vent screw of the filter housing has to be positioned at the highest point, to make sure that cpl. water system will be vented and completely drained. 2 Install water filter assy (25). (e) Installation of manual operation assy (60) 1 Install mounting angle (10, fig 26). 2 Install bracket (5, fig 26) with countersunk screws (15, fig 26). 3 Install operation label (40, fig 26). 4 Install bowden cable (35, fig 26) to bowden wire (30, fig 26) with bushings (65, fig 26). 5 Install bowden cable (35, fig 26) with bowden wire (30, fig 26). 6 Install adjusting screw (25, fig 26) to mounting angle (10, fig 26) with hexagonal nuts (70, fig 26). 7 Install end parts (60, fig 26) to bowden cable (35, fig 26).
(c) (d)
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8 Install bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 9 Install knob (45, fig 26) to bolt (50, fig 26). 10 Connect bowden wire (30, fig 26) and bowden cable (35, fig 26) to bolts (20, fig 26; 50, fig 26) with end parts (60, fig 26) and bushings (65, fig 26). (f) (g) (5) Install bonding clips (190, 195). Check water installation assy per chapter CHECK.
Water installation assy - Unit G5 (refer IPC, fig 9D) (a) Install bracket (10), drain stop valve bracket (15) and mounting brackets (5) with countersunk screws (65), hexagonal screws (70), lock wahers (85) and washers (80). Install distance sleeves (55, 60), drain stop valve (20), reducing part (30), elbow (35), hoses (90, 95) and tubes (100, 105, 110) with hexagonal screws (75), lock washers (85), washers (80) and clamps (40, 45, 50). Installation of manual operation assy (25) 1 Install mounting angle (10, fig 26). 2 Install bracket (5, fig 26) with countersunk screws (15, fig 26). 3 Install operation label (40, fig 26). 4 Install bowden cable (35, fig 26) to bowden wire (30, fig 26) with bushings (65, fig 26). 5 Install bowden cable (35, fig 26) with bowden wire (30, fig 26). 6 Install adjusting screw (25, fig 26) to mounting angle (10, fig 26) with hexagonal nuts (70, fig 26) 7 Install end parts (60, fig 26) to bowden cable (35, fig 26). 8 Install bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 9 Install knob (45, fig 26) to bolt (50, fig 26). 10 Connect bowden wire (30, fig 26) and bowden cable (35, fig 26) to bolts (20, fig 26; 50, fig 26) with end parts (60, fig 26) and bushings (65, fig 26). (d) Check water installation assy per chapter CHECK.
(b)
(c)
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(6)
Water installation assy - Unit G6 (refer IPC, fig 9E) (a) Install coffee maker rail (295) and mounting brackets (5, 10, 15, 20) with countersunk screws (225), hexagonal screws (215), pan-head screws (205) and washer (240). Install shut off valve (65), water spigot (70), exhaust valve (75), double nipples (80, 85), elbows (90, 95, 100), sleeves (175, 180), distance sleeves (185), T-fittings (115, 120, 125, 130), hoses (245, 250, 250, 285) and tubes (-305, -325, 330, 335, 340, 345) with hexagonal screws (220), lock washers (230), washers (235), hexagonal nuts (135, 140) and clamps (160). Install drain valve (55),elbow (105), T-fittings (110), insulating hoses (290), hoses (260, 265, 270, 275), sealing tapes (350) and tubes (300, 310, 315, 320) with hexagonal screws (210, 220), lock washers (230), washers (235), spacer (145) and clamps (150, 155, 165, 170). Installation of water filter assy (25) 1 Install reinforcing rings (50) to water filter assy (25). 2 Install gasket (-30) and cartridge (-35) to water filter assy (25). NOTE: After replacing of the water filter cartridge in the water filter it must be strictly mandatory that the vent screw of the filter housing has to be positioned at the highest point, to make sure that cpl. water system will be vented and completely drained. 3 Install filter supports (40, 45) and water filter assy (25) with hexagonal screws (210), lock washers (230) and washers (235). (e) Installation of manual operation assy (60) 1 Install mounting angle (10, fig 26) with hexagonal screws (210), lock washers (230) and washers (235). 2 Install bracket (5, fig 26) with countersunk screws (15, fig 26). 3 Install operation label (40, fig 26). 4 Install bowden cable (35, fig 26) to bowden wire (30, fig 26) with bushings (65, fig 26). 5 Install bowden cable (35, fig 26) with bowden wire (30, fig 26). 6 Install adjusting screw (25, fig 26) to mounting angle (10, fig 26) with hexagonal nuts (70, fig 26). 7 Install end parts (60, fig 26) to bowden cable (35, fig 26).
(b)
(c)
(d)
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8 Install bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 9 Install knob (45, fig 26) to bolt (50, fig 26). 10 Connect bowden wire (30, fig 26) and bowden cable (35, fig 26) to bolts (20, fig 26; 50, fig 26) with end parts (60, fig 26) and bushings (65, fig 26). (f) (g) (7) Install bonding clips (190, 195, 200). Check water installation assy per chapter CHECK.
Water installation assy - Unit G7 (refer IPC, fig 9F) (a) (b) Install mounting brackets (5, 10) with hexagonal screws (95), lock washers (105) and washers (110). Install shut off valve (15), exhaust valve (20), coupling nipples (25) with gasket (30), double nipples (35, 40, 45), elbows (50, 55), T-fittings (60), fitting (65), sleeves (90), hose (130), insulating hose (135) sealing tape (140) and tubes (145, 150, 155, 160, 165, 170, 175, 180) with lock washers (105), washers (110), spacers (115), clamps (70) and hexagonal nuts (75, 80, 85, 100). Install bonding clips (120, 125). Check water installation assy per chapter CHECK.
(c) (d) (8)
Water installation assy - Unit G4A (refer IPC, fig 9G) (a) (b) (c) Install mounting brackets (5, 10). Install drain valve (15), adapter (25), spacer (30) and hoses (35, 40, 45, 50,70, 75) with clamps (55, 60, 65). Installation of manual operation assy (20) 1 Install mounting angle (10, fig 26). 2 Install bracket (5, fig 26) with countersunk screws (15, fig 26). 3 Install operation label (40, fig 26). 4 Install bowden cable (35, fig 26) to bowden wire (30, fig 26) and bushings (65, fig 26). 5 Install bowden cable (35, fig 26) with bowden wire (30, fig 26).
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6 Install adjusting screw (25, fig 26) to mounting angle (10, fig 26) with hexagonal nuts (70, fig 26). 7 Install end parts (60, fig 26) to bowden cable (35, fig 26). 8 Install bolts (20, fig 26; 50, fig 26) and springs (55, fig 26). 9 Install knob (45, fig 26) to bolt (50, fig 26). 10 Connect bowden wire (30, fig 26) and bowden cable (35, fig 26) to bolts (20, fig 26; 50, fig 26) with end parts (60, fig 26) and bushings (65, fig 26). (d) N. Check water installation assy per chapter CHECK.
Ventilation Systems Unit G1, G4, G6 And G7 (1) Ventilation system Unit G3 (refer IPC, fig 10) (a) (b) (c) (d) (e) (f) Install brackets (165), elbow (150), sleeve (160) and hose (155) to airplane supply system with pan-head screws (40), washers (45) and clamps (170). Install hose (65), sleeve (70) and tube (60) to air duct with clamp (75) and pan-head rivet (180). Install bracket (95), sleeve (70), hose (85) and tube (60) to elbow (150) with pan-head screws (40), washers (45) and clamp (75). Install hose (80) to hose (65) and to bracket (95) with clamps (75). Install bracket (95), sleeve (70) and hose (90) to hose (80) with pan-head screws (40), washers (45) and clamp (75). Installation of air flap assy (105) 1 Install air flap (110) to tube (130) with countersunk screw (135) and washers (140, 145). 2 Install handle (115) and to tube (130) with pan-head screw (120) and washer (125). 3 Install bracket (95) and air flap assy (105) to hose (90) with clamp (75). (g) Install brackets (95), sleeve (70) and hose (100) to air flap assy (95) with pan-head screws (40), washers (45) and clamps (75, 175).
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(h) (i) (2)
Install distance sleeve (50), sleeve (30) and hose (25) to airplane supply system with pan-head screws (40), washer (45) and clamps (35, 55). Install cap (10), bushing (15) and air outlet (5) to hose (25) with clamp (20).
Ventilation system Unit G4 (refer IPC, fig 10A) (a) (b) (c) (d) (e) (f) Install cap (125), bushing (125) and air outlet (5) to hose (115) with clamp (80). Install sleeve (85) and hose (115) to airplane supply system with clamp (80). Install sleeves (90) and hose (100) to T-fitting (10) and to airplane supply system with clamps (75). Install support (15), sleeve (90), hose (95) and T-fitting (10) to support (15) with pan-head screws (20), washers (25) and clamps (75). Install support (15) and hose (105) to air flap assy (30) with pan-head screws (20), washers (25) and clamps (75). Installation of air flap assy (30) 1 Install air flap (35) to tube (55) with countersunk screw (60) and washers (65, 70). 2 Install handle (40) to tube (55) with pan-head screw (45) and washer (50). 3 Install air flap assy (30) and clamp (75) to hose (105). (g) Install hose (110) to air duct with clamp (75).
(3)
Ventilation system Unit G6 (refer IPC, fig 10B) (a) (b) (c) (d) Install support (15), sleeve (105) and hoses (125, 130) to airplane supply system with pan-head screws (25), washers (30) and clamps (80). Install air flap assy (35) to support (15). Install supports (15), sleeve (105) and hose (135) to air flap assy (35) with pan-head screws (25), washers (30) and clamps (80, 95). Install support (15), sleeve (105) and hoses (115, 130) to airplane supply system with pan-head screws (25), washers (30) and clamps (80, 95).
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(e)
Installation of air flap assy (35) 1 Install handle (45) to tube (60) with pan-head screw (50) and washer (55). 2 Install air flap (40) to tube (60) with countersunk screw (65) and, washers (70, 75). 3 Install air flap assy (35) to support (15) with clamp (95).
(f) (g) (h) (4)
Install supports (15), sleeve (105) and hose (120) to air flap assy (35) with pan-head screw (25), washer (30) and clamp (95). Install support (20), sleeve (100) and hose (110) to airplane supply system with pan-head screws (25), washers (30) and clamps (85, 90). Install bushing (10) and air outlet (5) to hose (110).
Ventilation system Unit G7 (refer IPC, fig 10C) (a) (b) (c) (d) Install T-fitting (30), sleeve (110) and hose (135) to air duct with clamps (100). Install supports (15), sleeve (110) and hose (125) to T-fitting (30) with pan-head screws (20), washers (25) and clamps (100). Install supports (15), sleeve (110) and hose (130) to T-fitting (30) with pan-head screws (20) and washers (25). Installation of air flap assy (35) 1 Install handle (45) to tube (60) with pan-head screw (50) and washer (55). 2 Install air flap (40) to tube (60) with countersunk screw (65) and washers (70, 70). 3 Install air flap assy (35) to support (15) with clamp (80). (e) (f) (g) Install sleeve (110) and hose (120) to air flap assy (35) with clamps (80). Install sleeve (105) and hose (115) to airplane supply system with pan-head screws (20), washers (25) and clamps (85, 90). Install bushing (10) and air outlet (5) to hose (115) with clamp (95).
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O.
Cooling Systems - Unit G2, G4, G6 And G7 (1) Cooling system - Unit G2 (refer IPC, fig 11) (a) (b) (c) (d) Install sealing profile (180) and shim (175). Install plate (160) and extrusion (185). Install air grid (165) with countersunk screws (170). Installation of air duct assy (5) 1 Install sealing tapes (35) to air duct assy (5). 2 Install supports (10) to air duct assy (5) with pan-head screws (15) and washers (20). 3 Install air duct assy (5) with pan-head screws (125) and washers (130). (e) Installation of air baffle assy (150) 1 Install extrusion (155) to air baffle assy (150). 2 Install air baffle assy (150) with pan-head screws (125) and washers (130). (f) Installation of air baffle assemblies (65, 95) 1 Install extrusions (70, -100) and sealing profiles (75, -105) to air baffle assemblies (65, 95) with pan-head screws (80, -110), washers (85, -115) and hexagonal nuts (90, -120). 2 Install air baffle assemblies (65, 95) with pan-head screws (125) and washers (130). (g) Installation of air duct assy (40) 1 Install sealing tapes (60) to air duct assy (40). 2 Install supports (45) to air duct assy (40) with pan-head screws (50) and washers (55). 3 Install air duct assy (40) with pan-head screws (125) and washers (130). (h) (i) Install hoses (135, 140) to air duct assy (40) and to airplane supply system with clamps (145). Check cooling system per chapter CHECK.
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(2)
Cooling system - Unit G4 (refer IPC, fig 11A) (a) (b) (c) Install shim (125). Install air baffle (130). Installation of bellow assemblies (35, 95) 1 Install bellows (40, 100), flanges (45, 105) and frames (50, 110) to bellow assemblies (35, 95) with pan-head screws (55, 115) and washers (60, 120). 2 Install bellow assemblies (35, 95) with hexagonal screws (140) and washers (145). (d) Installation of air duct assemblies (5, 65) 1 Install shims (30, 90) to air duct assemblies (5, 65). 2 Install air grids (20, 80) to air duct assy (5) with countersunk screws (25, 85). 3 Install supports (10, 70) to air duct assemblies (5, 65) with pan-head screws (15, 75). 4 Install air duct assemblies (5, 65) with pan-head screws (135). (e) Check cooling system per chapter CHECK.
(3)
Cooling system - Unit G6 (refer IPC, fig 11B) (a) (b) Install plate (250). Installation of air baffle assemblies (190, 220) 1 Install extrusions (195, -225) and sealing profiles (200, -230) to air baffle assemblies (190, 220) with pan-head screws (205, -235), washers (210, -240) and hexagonal nuts (215, -245). 2 Install air baffle assemblies (190, 220) with pan-head screws (110) and washers (115). (c) Installation of connection tube assemblies (140, 155) 1 Install sealing tapes (145, 160) and foam plates (150) to tube assemblies (140, 155). 2 Install connection tube assemblies (140, 155) with hexagonal screws (165) and washers (170).
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(d) (e)
Install air grids (120, 125, 130, 135) with pan-head screws (110) and washers (115). Installation of air duct assemblies (5, 30, 50, 70, 90) 1 Install sealing tapes (20, 25, 45, 65, 85, 105) to to air duct assemblies (5, 30, 50, 70, 90). 2 Install supports (10, 35, 55, 75, 95) to air duct assemblies (5, 30, 50, 70, 90) with pan-head screws (15, 40, 60, 80, 100). 3 Install air duct assemblies (5, 30, 50, 70, 90) with pan-head screws (110) and washers (115).
(f) (g) (4)
Install hoses (175, 180) to air duct assemblies (5, 35) and to connection tube assemblies (140, 155) with clamps (185). Check cooling system per chapter CHECK.
Cooling system - Unit G7 (refer IPC, fig 11C) (a) Installation of air baffle assemblies (170, 200) 1 Install extrusions (175, -205) and sealing profiles (180, -210) to air baffle assemblies (170, 200) with pan-head screws (185, -215), washers (190, -220) and hexagonal nuts (195, -225). 2 Install air baffle assemblies (170, 200) with pan-head screws (90) and washers (95). (b) Installation of connection tube assemblies (120, 135) 1 Install sealing tapes (125, 140) and foam plates (130) to connection tube assemblies (120, 135). 2 Install connection tube assemblies (120, 135) with hexagonal screws (145) and washers (150). (c) (d) Install air grids (100, 105, 110, 115) with pan-head screws (90) and washers (95). Installation of air duct assemblies (5, 30, 55, 75) 1 Install sealing tapes (20, 25, 45, 50, 70) to air duct assemblies (5, 30, 55, 75). 2 Install supports (10, 35, 60, 80) to air duct assemblies (5, 30, 55, 75) with pan-head screws (15, 40, 65, 85).
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3 Install air duct assemblies (5, 30, 55, 75) with pan-head screws (90) and washers (95). (e) (f) P. Install hoses (155, 160) to air duct assemblies (5, 30) and to connection tube assemblies (120, 135) with clamps (165). Check cooling system per chapter CHECK.
Lower Part Assemblies Units G1, G4, G6, G7, G4A (1) Lower part assy - Unit G1 (refer IPC, fig 5) (a) (b) (c) (d) (e) (f) (g) (h) (i) Install bumpers (325, 335, 350) and shims (330, 340) to lower part assy (-1). Install access cover (415) to lower part assy with countersunk screws (420). Install lower attachment bracket (355, 380) to lower part assy with countersunk screws (295), pan-head screws (360) and washers (290). Install lower attachment brackets (280) to lower part assy with countersunk screws (295), pan-head screws (285) and washers (290). Install lower attachment bracket (265) to lower part assy with countersunk screws (270). Install extrusions (250, 255) and sealing profile (245) to lower part assy with pan-head screws (260) and washers (140). Install extrusions (235) and sealing profile (230) to lower part assy with pan-head screws (240) and washers (140). Install access cover (225) to lower part assy with countersunk screws (205). Installation of cover assemblies (300, 365, 385, 400) 1 Install plate (305, 370, 390, 410) and sealing profile (310, 375, 390, 405) to cover assemblies (300, 365, 385, 400). 2 Install cover assemblies (300, 365, 385, 400) to lower part assy with countersunk screws (320), pan-head screws (315) and washers (140). (j) Installation of cover assy (210) 1 Install plate (215) to cover assy (210).
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2 Install cover assy (210) to lower part assy with countersunk screws (205, 220). (k) Installation of cover assy (180) 1 Install sealing profiles (185) to cover assy (180). 2 Install sealing profile (185) and plates (190, 195) to cover assy (180) with countersunk rivets (200). 3 Install cover assy (180) to lower part assy with countersunk screws (205). (l) Installation of cover assy (145) 1 Install strike (165) to cover assy (145) with countersunk screws (170). 2 Install extrusions (150, 155) to cover assy (145) with pan-head rivets (160). 3 Install cover assy (145) to lower part assy with pan-head rivets (175). (m) Installation of guide assemblies (65, 95, 115, 125) 1 Install sliding strips (70, 100, 120, 130) to guide assemblies (65, 95, 115, 125). 2 Install guide assemblies (65, 95, 115, 125), extrusions (235) and sealing profiles (230) to lower part assy with pan-head screws (135) and washers (140). (n) Installation of guide assemblies (75, 85, 105 1 Install sliding strips (80, 90, 110) to guide assemblies (75, 85, 105). 2 Install guide assemblies (75, 85, 105) to lower part assy with pan-head screws (135) and washers (140). (o) Installation of door assemblies (15, 25, 45, 55) 1 Install door assemblies (15, 25, 35, 45, 55) to lower part assy with pan-head screws (20, 30, 40, 50, 60). (p) Installation of folding door assemblies (5) 1 Install folding door assy (5) to lower part assy with pan-head screws (10).
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(2)
Lower part assy unit G4 (refer IPC, fig 5A) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Install bumpers (95), shims (100), guides (180) and sliding strips (205, 240) to lower part assy (-1). Install strike (210) to lower part assy with countersunk screws (215). Install air grid (195) to lower part assy. Install extrusions (185, 200) to lower part assy with pan-head screws (85). Install lower attachment brackets (190) to lower part assy with countersunk screws (250), pan-head screws (255) and washers (260). Install lower attachment brackets (140) to lower part assy with countersunk screws (245). Install extrusion (225), retainer (220) and sealing profile (75) to lower part assy with countersunk rivets (230) and countersunk screws (235). Install bumpers (95) and shims (100) to lower part assy with pan-head screws (85). Install extrusions (80) and sealing profiles (70) to lower part assy with pan-head screws (85). Installation of access cover assemblies (145, 160) 1 Install fasteners (150, 165) and washers (155, 170) to access cover assemblies (145, 160). 2 Install access cover assemblies (145, 160) and secure with fasteners (150, 165). (k) Installation of extrusion assy (105) 1 Install extrusion (115), sealing profile (110) to extrusion assy (105) with pan-head screws (120), washers (125) and hexagonal nuts (130). 2 Install extrusion assy (105) to lower part assy with pan-head screws (135) (l) Installation of guide assemblies (50, 60) 1 Install sliding strips (55, 65) to guide assemblies (50, 60). 2 Install guide assemblies (50, 60) to lower part assy with pan-head screws (85).
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(m) (n)
Install waste chute (40) to lower part assy with countersunk screws (45). Installation of waste container (35) 1 Open door and install waste container assy (35) to compartment 412.
(o)
Installation of door assy (25) 1 Install door assy (25) to lower part assy with pan-head screws (30).
(p)
Installation of insulated folding door assy (15) 1 Install insulated folding door assy (15) to lower part assy with pan-head screws (20).
(q)
Installation of insulated door assemblies (5) 1 Install insulated door assy (5) to lower part assy with pan-head screws (10).
(3)
Lower part assy Unit G6 (refer IPC, fig 5B) (a) (b) (c) (d) (e) (f) (g) (h) (i) Install bumpers (125, 130, 135), sealing profile (410), guides (180, 185, 270) and shims (140, 220) to lower part assy (-1). Install extrusion (405) and to lower part assy. Install access cover (120) to lower part assy. Install extrusions (215, 220) to lower part assy with countersunk screws (60). Install covers (290, 295) to lower part assy with countersunk screws (300). Install extrusions (190, 195) and sealing profile (200) to lower part assy with pan-head screws (210) and washers (100). Install extrusions (110) and sealing profile (115) to lower part assy with pan-head screws (95) and washers (100). Install lower attachment brackets (55, 145, 230, 275, 325) to lower part assy with countersunk screws (60), pan-head screws (65) and washers (70). Install covers (280, 285, 340) to lower part assy with pan-head screws (90, 95) and washers (100).
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(j)
Installation of cover assy (365) 1 Install sliding strip (-375) and sealing profile (-380) to cover assy (365). 2 Install plate (-370) and to cover assy (365). 3 Install cover assy (365) to lower part assy with countersunk screws (170), pan-head screws (90) and washers (100).
(k)
Installation of cover assy (330) 1 Install sliding strip (-335) to cover assy (330). 2 Install cover assy (330) to lower part assy with countersunk screws (300), pan-head screws (95) and washers (100).
(l)
Installation of cover assy (150) 1 Install sliding strips (-160) and sealing profiles (-165) to cover assy (150). 2 Install plates (-155) to cover assy (150). 3 Install cover assy (150) to lower part assy with countersunk screws (170), pan-head screws (90) and washers (100).
(m)
Installation of cover assemblies (75, 235) 1 Install sealing profiles (-85, -240) to cover assemblies (75, 235). 2 Install plates (-80, -245) to cover assemblies (75, 235). 3 Install cover assemblies (75, 235) with pan-head screws (90, 95) and washers (100).
(n)
Installation of guide assemblies (305, -315, 345, 355, 385, 395) 1 Install sliding strips (310, -320, 350, 360, 390, 400) to guide assemblies (305, -315, 345, 355, 385, 395). 2 Install guide assemblies (305, -315, 345, 355, 385, 395) to lower part assy with pan-head screws (95, 210) and washers (100).
(o)
Installation of guide assy (260) 1 Install sliding strip (-265) to guide assy (260).
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2 Install guide assy (260) to lower part assy with countersunk screws (170) and washers (100). (p) Installation of box assy (30) 1 Install supports (35), shims (50) and box assy (30) to lower part assy with pan-head screws (40) and washers (45). (q) Installation of casing assy (5) 1 Install supports (10) shims (25) and casing assy (5) to lower part assy with pan-head screws (15) and washers (20). (4) Lower part assy unit G7 (refer IPC, fig 5C) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Install bumpers (125, 130, 135), shims (140, 200), guides (190, 195) and sliding strip (220) to lower part assy. Install plate (350) to lower part assy. Install covers (295, 370) to lower part assy with pan-head screws (90, 95) and washers (100). Install extrusions (230, 235) to lower part assy with countersunk screws (60). Install extrusions (210, 205) and sealing profiles (215) to lower part assy with pan-head screws (225) and washers (100). Install bracket (145) to lower part assy with countersunk screws (150). Install access cover (120) to lower part assy. Install extrusions (110) and sealing profiles (115) to lower part assy with pan-head screws (95) and washers (100). Install lower attachment brackets (55, 155, 240, 290, 355) to lower part assy with countersunk screws (60), pan-head screws (65) and washers (70). Installation of cover assemblies (360, 420) 1 Install sliding strips (365, 420) to cover assemblies (360, 420). 2 Install cover assemblies (360, 420) to lower part assy with countersunk screws (395), pan-head screws (90, 95) and washers (100).
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(k)
Installation of cover assemblies (260, 400) 1 Install sliding strips (-170, -410) and sealing profiles (-175, 415) to cover assemblies (260, 400). 2 Install plates (-165, -405) to cover assemblies (260, 400). 3 Install cover assemblies (260, 400) with countersunk screws (180), pan-head screws (90) and washers (100).
(l)
Installation of cover assemblies (75, 245, 300) 1 Install sliding strip (-310) and sealing profiles (-85, -255, -315) to cover assemblies (300). 2 Install plates (-80, -250, -305) to cover assemblies (75, 245, 300). 3 Install cover assemblies (75, 245, 300) to lower part assy with countersunk screws (180), pan-head screws (90, 95) and washers (100).
(m)
Installation of guide assemblies (270, 375, 385, 430, 440) 1 Install sliding strips (275, 325, -335, 380, 390, 435, -445) to cover assemblies (270, 375, 385, 430, 440). 2 Install extrusions (260, 340, 450), sealing profiles (265, 455, 345) and cover assemblies (270, 375, 385, 430, 440) to lower part assy with pan-head screws (95, 225) and washers (100).
(n)
Installation of casing assemblies (5, 30) 1 Install supports (10, 35), shims (25, 50) and casing assemblies (5, 30) to lower part assy with pan-head screws (15, 40) and washers (20, 45).
(5)
Lower part assy Unit G4A (refer IPC, fig 5D) (a) (b) (c) (d) (e) Install bumpers (180, 210), sliding strips (105, 125, 170, 220, 240) and shims (110, 130, 175, 185, 215) to lower part assy (-1). Install fasteners (230) to cover (225). Install cover (225) to lower part assy and secure with countersunk rivets (235) and fasteners (230). Install end parts (200) and protecting strip (190) to lower part assy with pan-head screws (205). Install filling strip (195) to protecting strip (190).
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(f) (g) (h)
Install cover (165) to lower part assy. Install single revolving catches (145, 150) and double revolving catches (160) to lower part assy with pan-head screws (155). Installation of revolving catch assy (135) 1 Install bushings (55, fig 21A; 65, fig 21A) to support (5, fig 21A) 2 Install support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) to upper part assy with pan-head screws (140). 3 Install axle (10, fig 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) to support (5, fig 21A) with setscrew (60, fig 21A) and ball catch (40, fig 21A). 4 Install cover (25, fig 21A) to support (5, fig 21A) with countersunk screws (20, fig 21A). 5 Install knob (30, fig 21A) and washer (15, fig 21A) to axle (10, fig 21A) with slotted pin (35, fig 21A).
(i) (j) (k) (l)
Install strikes (115) to lower part assy with countersunk screws (120). Install brackets (85, 95) to lower part assy with countersunk screws (90). Install lower attachment brackets (75) to lower part assy with countersunk screws (80). Installation of guide assemblies (50, 65) 1 Install sliding strips (55, 70) to guide assemblies (50, 65). 2 Install guide assemblies (50, 65) to lower part assy with pan-head screws (60).
(m)
Installation of waste container (45) 1 Open door and install waste container assy (45) to compartment 4A07.
(n)
Installation of door assemblies (5, 15, 25, 35) 1 Install door assemblies (5, 15, 25, 35) to lower part assy with countersunk screws (10, 20, 30, 40).
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Q.
Upper Part Assemblies Unit G1, G2, G3, G4 And G5 (1) Upper part assy unit G1 (refer IPC, fig 6) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) Install work counter tops (70, 75, 80), guides (550, 670), sliding strips (600) and shims (605) to upper part assy (-1). Install shell (675) to upper part assy with countersunk screws (280). Install upper attachment bracket (635) to upper part assy with countersunk screws (640), washers (645) and hexagonal nuts (650). Install bumper (620) and shim (625) to upper part assy with countersunk screws (630). Install extrusion (595) to upper part assy with countersunk screws (115). Install plate (590) to upper part assy with countersunk screws (565). Install guide (555) and spacers (560) to upper part assy with countersunk screws (565). Install support (545) to upper part assy with pan-head screws (120). Install bumpers (530) and shims (535) to upper part assy with countersunk screws (540). Install upper attachment bracket (485) to upper part assy with hexagonal screws (490) and washers (495). Install ball catch (395) and plates (405, 400) to upper part assy with countersunk screws (410). Install sieve (395) to upper part assy with countersunk screws (390). Install extrusions (-370, 375, 380) to upper part assy with pan-head screws (120). Install extrusion (350) to upper part assy. Install air grids (330, 335) to upper part assy with pan-head screws (120). Install extrusions (315, 320), spacer (340) and plate (345) to upper part assy with countersunk screws (280). Install extrusions (290, 295, 300, 305, 310) to upper part assy with countersunk screws (325).
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(r) (s) (t) (u) (v) (w) (x)
Install air grid (285) to upper part assy with pan-head screws (120). Install extrusion (275) to upper part assy with countersunk screws (280). Install access cover (-270) to upper part assy. Install extrusion (265) to upper part assy with pan-head screws (65) and countersunk screws (115). Install extrusion (255) to upper part assy with pan-head screws (260). Install covers (105, 110) to upper part assy with countersunk screws (115) and pan-head screws (120). Installation of revolving catch assy (610) 1 Install bushings (55, fig 21A; 65, fig 21A) to support (5, fig 21A) 2 Install support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) to upper part assy with countersunk screws (615). 3 Install axle (10, fig 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) to support (5, fig 21A) with setscrew (60, fig 21A) and ball catch (40, fig 21A). 4 Install cover (25, fig 21A) to support (5, fig 21A) with countersunk screws (20, fig 21A). 5 Install knob (30, fig 21A) and washer (15, fig 21A) to axle (10, fig 21A) with slotted pin (35, fig 21A).
(y)
Installation of revolving catch assy (580) 1 Install bushing (40, fig 21) and distance bushing (25, fig 21) to support (5, fig 21). 2 Install support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) to upper part assy with pan-head screws (585). 3 Install axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) to support (5, fig 21) with setscrew (45, fig 21) and ball catch (30, fig 21). 4 Install knob (60, fig 21) and distance bushing (20, fig 21) to axle (10, fig 21) with slotted pin (35, fig 21).
(z)
Installation of drip pan assy (655) 1 Install sieve (660) to drip pan assy (655) with countersunk screws (665).
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2 Install drip pan assy (655) to upper part assy. (za) Installation of air screen assy (505) 1 Install filter pad (515) to air screen assy with retainer (510). 2 Install fasteners (520) to air screen assy (505). 3 Install air screen assy (505) to upper part assy and secure with fasteners (520). (zb) (zc) Install exhaust hood (500) to upper part assy with pan-head screws (120). Installation of air screen box assy (415) 1 Install tube (445) to air screen box assy (415) with pan-head screws (450) and hexagonal nuts (455). 2 Installation of air screen assy (420) a Install filter pad (425) to air screen assy (420) with retainer (430). b Install fastener (435) and washer (440) to air screen assy (420). c Install air screen assy (420) to air screen box assy (415) and secure with fastener (435). 3 Install air screen box assy (415) to upper part assy with pan-head screws (120). (zd) Installation of plug support assemblies (195, 225) 1 Install alignment bushings (215, 245) to plug support assemblies (195, 225) with pan-head screws (220, 250). 2 Install spacers (200, 230) to plug support assemblies with countersunk rivets (210, 240) and countersunk screws (205, 235). 3 Install plug support assemblies (195, 225) to upper part assy with pan-head screws (120). (ze) Installation of outlet cover assy (460) 1 Install cover (465) to outlet cover assy (460) with pan-head screws (470) and washers (475). 2 Install outlet cover assy (460) to upper part assy with countersunk screws (480).
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(zf)
Installation of cover assemblies (175, -355) 1 Install velcros (180, 190, -360, -365) to cover assemblies (175, -355). 2 Install closing cap (185) to cover assy (175). 3 Install cover assemblies (175, -355) to upper part assy.
(zg)
Installation of support assemblies (125, 135, 145, -155, 165) 1 Install sliding strips (130, 140, 150, -160, 170) to support assemblies (125, 135, 145, -155, 165). 2 Install support assemblies (125, 135, 145, -155, 165) to upper part assy with pan-head screws (120).
(zh) (zi)
Install perforated cover (100) to sink assy (85) with countersunk screws (480). Installation of sink assy (85) 1 Install sieve (90) to sink assy (85) with countersunk screws (95). 2 Install sink assy (85) to upper part assy.
(zj)
Installation of disengaging installation devise (45) 1 Install disengaging installation assy (45) to upper part assy with countersunk screws (65), pan-head screws (55), bushings (60) and threaded bushings (50).
(zk)
Installation of hot cup retainer assy (35) 1 Install hot cup retainer assy (35) to upper part assy with countersunk screws (40).
(zl)
Installation of sliding work table assemblies (15, 25) 1 Install retainers (20, 30) to sliding work table assemblies (15, 20). 2 Install sliding work table assemblies (15, 25) to upper part assy and secure with retainers (20, 30).
(zm)
Installation of door assy (5) 1 Install door assy (5) to upper part assy with pan-head screws (10).
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(2)
Upper part assy Unit G4 (refer IPC, fig 6A) (a) Install extrusions (300, -345), sliding strips (305, 310, 315, 360, 445, 560, 565, 630, 635, 655, 665) and shims (450, -515, -520) to upper part assy (-1). Install cover (725) to upper part assy with pan-head screws (135). Install cover (-715) to upper part assy with pan-head screws (-720), washers (285). Install extrusions (300, -345) to upper part assy. Install bonding clip (-495) to upper part assy. Install access cover (645) to upper part assy with countersunk screws (45). Install strike (640) to upper part assy with countersunk screws (340). Install bumpers (355) to upper part assy with countersunk screws (45). Install extrusions (525, 530) and sliding strips (535, 540) to upper part assy with pan-head screws (45). Install extrusion (440, -570, 650, 660) to upper part assy. Install extrusions (425, 430) to upper part assy with countersunk screws (435). Install extrusion (415) and shims (455, 460) to upper part assy with countersunk screws (420). Install waste cover (410) to upper part assy with countersunk screws (45). Install guides (375) to upper part assy with countersunk screws (275). Install extrusion (355) to upper part assy with countersunk screws (340). Install roller blind latch (350) to upper part assy with countersunk screws (325). Install extrusion (335) to upper part assy with countersunk screws (340). Install extrusion (330) to upper part assy with pan-head screws (135). Install roller blind latch (320, 350) to upper part assy with countersunk screws (325).
(b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s)
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(t) (u) (v) (w) (x) (y) (z) (za) (zb) (zc) (zd)
Install extrusion (280) to upper part assy with pan-head screws (135) and washers (285). Install extrusion (260), spacers (265) and sliding strips (270) to upper part assy with countersunk screws (195, 275). Install extrusion (245) to upper part assy with pan-head screws (250) and washers (255). Install upper attachment brackets (225, 230) to upper part assy with hexagonal screws (235) and washers (240). Install extrusions (210) to upper part assy with countersunk screws (215, 220). Install spacers (200) to upper part assy with countersunk screws (205). Install extrusion (185) to upper part assy with countersunk screws (90, 95). Install cover (175) to upper part assy with countersunk screws (180) and with pan-head screws (135). Install air grids (140, 145, -150, 155, -160, -165, 170) to upper part assy. Install cover (130) to upper part assy with pan-head screws (135). Installation of sink complete assy (670) 1 Install shim (-700) to sink complete assy (670). 2 Installation of sink assy (675) a Install sieve (-680) to sink assy (675) with countersunk screws (-685). b Install sink assy (675) to sink complete assy (670). 3 Install extrusion (-705) and work counter top (695) to sink complete assy (670) with countersunk screws (-710). 4 Install perforated cover (690) to sink assy (675).
(ze)
Installation of air screen box assy (575) 1 Install air grid (-600) and tube (-605) to air screen box assy (575) with pan-head screws (-610) washers (-615) and hexagonal nuts (-620).
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2 Installation of air screen assy (580) a Install filter pad (-585) to air screen assy (580) with retainer (-590). b Install fastener (-595) to air screen assy (580). c Install air screen assy (580) to air screen box assy (575) and secure with fastener (-595). 3 Install air screen box assy (575) to upper part assy with pan-head screws (625). (zf) Installation of revolving catch assy (545) 1 Install bushings (55, fig 21A; 65, fig 21A) to support (5, fig 21A) 2 Install support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) to upper part assy with countersunk screws (550). 3 Install axle (10, fig 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) to support (5, fig 21A) with setscrew (60, fig 21A) and ball catch (40, fig 21A). 4 Install cover (25, fig 21A) to support (5, fig 21A) with countersunk screws (20, fig 21A). 5 Install knob (30, fig 21A) and washer (15, fig 21A) to axle (10, fig 21A) with slotted pin (35, fig 21A). (zg) Installation of plug support assy (500) 1 Install cover (505) to plug support assy (500) with pan-head screws (510). 2 Install and plug support assy (500) to upper part assy with pan-head screws (135) and washers (285). (zh) Installation of drip pan assemblies (465, 480) 1 Install sieves (470, 485) to drip pan assemblies (465, 480) with countersunk screws (475, 490). 2 Install drip pan assemblies (465, 480) to upper part assy. (zi) Installation of waste flap assy (385) 1 Install knob (-400) to waste flap assy (385) with countersunk screws (-405).
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2 Install hinge (-390) to waste flap assy (385) with countersunk rivets (-395). 3 Install waste flap assy (385) to upper part assy with countersunk screws (215). (zj) Installation of revolving catch assy (365) 1 Install bushing (40, fig 21) and distance bushing (25, fig 21) to support (5, fig 21). 2 Install support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) to upper part assy with pan-head screws (370). 3 Install axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) to support (5, fig 21) with setscrew (45, fig 21) and ball catch (30, fig 21). 4 Install knob (60, fig 21) and distance bushing (20, fig 21) to axle (10, fig 21) with slotted pin (35, fig 21). (zk) Installation of plug support assy (100) 1 Install spacer (120) to plug support assy (100) with countersunk screws (125). 2 Install alignment bushings (105) to plug support assy (100) with pan-head screws (110) and washers (115). 3 Install plug support assy (100) to upper part assy with pan-head screws (135). (zl) Installation of work light assy (85) 1 Install work light (90) to work light assy (85) with pan-head screws (95). 2 Install work light assy (85) to upper part assy with pan-head screws (35). (zm) Installation of upper attachment assy (50) 1 Install upper attachment assy (50) to upper attachment brackets (225, 230) with hexagonal screws (55, 70), washers (60, 75) and hexagonal nuts (65, 80).
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(zn)
Installation of disengaging installation assy (25) 1 Install disengaging installation assy (25) to upper part assy with countersunk screws (45), pan-head screws (35), bushings (40) and threaded bushings (30).
(zo)
Installation of sliding work table (15) 1 Install retainer (20) to upper part assy (15). 2 Install sliding work table (15) to upper part assy and secure with retainer (20).
(zp)
Installation of door assy (5) 1 Install door assy (5) to upper part assy with countersunk screws (10).
(3)
Upper part assy unit G6 (refer IPC, fig 6B) (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) Install work counter tops (45, 50), guides (455, 485, 500, 655), shims (505, 510, 515, 535) and sliding strips (530) to upper part assy (-1). Install shell (690) to upper part assy with countersunk screws (195). Install cover (670) to upper part assy with pan-head screws (145) and washers (150). Install air grid (640) to upper part assy. Install extrusions (-625, 630, -635) to upper part assy with pan-head screws (145) and washers (150). Install air grids (615, 620) to upper part assy with pan-head screws (145) and washers (150). Install bumpers (580) and shims (575) to upper part assy with countersunk screws (205). Install guides (555, 610) to upper part assy with countersunk screws (205). Install bracket (525) to upper part assy with countersunk screws (205). Install access cover (495) to upper part assy with countersunk screws (205). Install extrusion (475) and sealing profile (480) to upper part assy with pan-head screws (145) and washers (150). Install metal sheet (450) to upper part assy.
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(m) (n) (o) (p) (q) (r) (s) (t)
Install mounting plate (440) and latch (435) to upper part assy with countersunk screws (445). Install strike (430) to upper part assy with countersunk screws (195). Install air grids (410) to upper part assy with pan-head screws (145, 650) and washers (150). Install access cover (-400), conduit (-415) and covers (-420, -425) to upper part assy. Install extrusion (380) to upper part assy with pan-head screws (385) and washers (390). Install extrusions (360, 365) to upper part assy with pan-head screws (145) and washers (150). Install spacer (320) to upper part assy with countersunk screws (170). Install eccentrical bushings (335, 340), shims (330) and upper attachment brackets (325, 370) to upper part assy with countersunk screws (350, 375), washers (315, 345) and hexagonal nuts (355). Install upper attachment bracket (325) to upper part assy with hexagonal screws (310) and washers (315). Install extrusion (285) to upper part assy with countersunk screws (170). Install extrusions (240, -245, 250, 255, 260, -265, 270, 275, -280) to upper part assy with countersunk screws (195). Install extrusions (230) to upper part assy with countersunk screws (205). Install extrusion (295) to upper part assy with pan-head screws (220, 300) and washers (150, 225). Install air boxes (210, 215) to upper part assy with pan-head screws (145) and washers (150). Install cup holder (200) to upper part assy with countersunk screws (205). Install paper clip (190) to upper part assy with countersunk screws (195). Install extrusions (160, 165) to upper part assy with countersunk screws (170), pan-head screws (145) and washers (150). Install cover (155) to upper part assy with pan-head screws (145) and washers (150).
(u) (v) (w) (x) (y) (z) (za) (zb) (zc) (zd)
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(ze)
Installation of hot cup retainer assy (680) 1 Install hot cup retainer assy (680) to upper part assy with countersunk screws (685).
(zf)
Installation of guide assy (660) 1 Install sliding strips (-665) to guide assy (660). 2 Install guide assy (660) and shims (290) to upper part assy with pan-head screws (145) and washers (150).
(zg)
Installation of air screen box assy (585) 1 Install tube (590) to air screen box assy (415) with pan-head screws (-595) and hexagonal nuts (-600). 2 Installation of air screen assy (601) a Install filter pad (-605) to air screen assy (601) with retainer (-603). b Install fastener (-603) and washer (-607) to air screen assy (601). c Install air screen assy (601) to air screen box assy (585) and secure with fastener (-603). 3 Install air screen box assy (585) to upper part assy with pan-head screws (120).
(zh)
Installation of drip pan assy (560) 1 Install sieve (565) to drip pan assy (560) with countersunk screws (570). 2 Install drip pan assy (560) to upper part assy.
(zi)
Installation of plug support assy (540) 1 Install cover (-545) to plug assy support (540) with pan-head screws (-550). 2 Install plug support assy (540) to upper part assy with pan-head screws (145) and washers (150).
(zj)
Installation of revolving catch assy (460) 1 Install bushing (40, fig 21) and distance bushing (25, fig 21) to support (5, fig 21).
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2 Install support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) to upper part assy with pan-head screws (465). 3 Install axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) to support (5, fig 21) with setscrew (45, fig 21) and ball catch (30, fig 21). 4 Install knob (60, fig 21) and distance bushing (20, fig 21) to axle (10, fig 21) with slotted pin (35, fig 21). (zk) Installation of cover assy (175) 1 Install fasteners (180) and washers (185) to cover assy (175). 2 Install cover assy (175) to upper part assy and secure with fasteners (180). (zl) Installation of plug support assemblies (85, 115) 1 Install alignment bushings (100, 130) to plug support assemblies (85, 115) with pan-head screws (105, 135) and washers (110, 140). 2 Install spacers (90, 120) to plug support assy (85, 115) with countersunk screws (95, 125). 3 Install plug support assemblies (85, 115) to upper part assy with pan-head screws (145) and washers (150). (zm) Installation of sink complete assy (55) 1 Installation of sink assy (60) a Install sieve (-65) to sink assy (60) with pan-head screws (-70). b Install sink assy (60) to sink complete assy (55). 2 Install extrusion (275) and work counter top (50) to sink complete assy (55) with countersunk screws (195). 3 Install perforated cover (80) to sink assy (55). (zn) Installation of sliding work table assy (35) 1 Install retainer (40) to sliding work table assy (35) 2 Install sliding work table (35) to upper part assy and secure with retainer (40).
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(zo)
Installation of door assy (5) 1 Install door assy (20) to upper part assy with countersunk screws (25) washers (30).
(zp)
Installation of insulated door assy (5) 1 Install insulated door assy (5) to upper part assy with countersunk screws (10) and washers (15).
(4)
Upper part assy Unit G7 (refer IPC, fig 6C) (a) Install work counter top (45), bumper (-205), guides (455, 460, 490, 650, -675), sliding strips (480, 595, -660, -685) and shims (465, 470, 495, 600) to upper part assy (-1). Install strikes (680) to upper part assy with countersunk screws (195). Install air grids (640) to upper part assy with pan-head screws (645) and washers (155). Install air grids (615, 620, 625, 630) to upper part assy with pan-head screws (150) and washers (155). Install guide (610) to upper part assy with countersunk screws (585). Install cover (605) to upper part assy with pan-head screws (150). Install bumpers (575) and shims (580) to upper part assy with countersunk screws (585). Install extrusion (560) and sealing profile (565) to upper part assy with pan-head screws (150) and washers (155). Install covers (520, 525) to upper part assy with pan-head screws (150) and washers (155). Install guides (500, 505, 510, 515) to upper part assy with countersunk screws (55). Install access cover (485) to upper part assy with countersunk screws (55). Install conduit (-445) and metal sheet (-450) to upper part assy. Install air cover (-425) to upper part assy. Install extrusion (440) to upper part assy with countersunk screws (55).
(b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n)
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(o) (p) (q) (r) (s)
Install cover (435) to upper part assy with pan-head screws (150) and washers (155). Install extrusion (405) to upper part assy with pan-head screws (410) and washers (415). Install extrusions (360, -365) to upper part assy with pan-head screws (150) and washers (155). Install spacer (320) to upper part assy with countersunk screws (245). Install eccentrical bushings (335, 340) shims (320) and upper attachment brackets (325, 395) to upper part assy with countersunk screws (350, 400), washers (315, 345) and hexagonal nuts (355). Install upper attachment bracket (305) to upper part assy with hexagonal screws (310) and washers (315). Install extrusion (290) to upper part assy with pan-head screws (280, 295) and washers (155, 285). Install extrusion (475) and shim (275) to upper part assy with pan-head screws (150) and washers (155). Install extrusions (265, 270) to upper part assy with countersunk screws (195). Install sealing profile (240) to upper part assy with countersunk screws (245). Install cover (235) to upper part assy with pan-head screws (150) and washers (155). Install extrusion (200) to upper part assy with pan-head screws (150) and washers (155). Install paper clip (190) to upper part assy with countersunk screws (195). Install extrusion (50) to upper part assy with countersunk screws (55). Installation of guide assemblies (-665, 695, 705) 1 Install sliding strips (-670, 700, 710) to guide assemblies (-665, 695, 705). 2 Install guide assemblies (-665, 695, 705) to upper part assy with pan-head screws (645) and washers (155).
(t) (u) (v) (w) (x) (y) (z) (za) (zb) (zc)
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(zd)
Installation of guide assy (550) 1 Install teflon (555) to guide assy (550). 2 Install guide assy (550) to upper part assy.
(ze)
Installation of revolving catch assy (535) 1 Install bushing (40, fig 21) and distance bushing (25, fig 21) to support (5, fig 21). 2 Install support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) to upper part assy with pan-head screws (540). 3 Install axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) to support (5, fig 21) with setscrew (45, fig 21) and ball catch (30, fig 21). 4 Install knob (60, fig 21) and distance bushing (20, fig 21) to axle (10, fig 21) with slotted pin (35, fig 21).
(zf)
Installation of air screen assy (375) 1 Install filter pad (385) to air screen assy (375) with retainer (380). 2 Install fastener (390) to air screen assy. 3 Install air screen assy (375) to upper part assy and secure with fasteners (390).
(zg) (zh)
Install extrusions (300) and exhaust hoods (370) to upper part assy with countersunk screws (55), pan-head screws (150) and washers (155). Installation of air duct assy (250) 1 Install shim (255) and sealing tape (260) to air duct assy (250). 2 Install air duct assy (250) to upper part assy.
(zi)
Installation of cover assy (210) 1 Install supports (220) and cover (215) to cover assy (210) with pan-head screws (-225) and washers (-230). 2 Install cover assy (210) to upper part assy with pan-head screws (150) and washers (155).
(zj)
Install washers (185) and cover assy (175) to upper part assy and secure with fasteners (180).
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(zk)
Installation of cover assy (160) 1 Install shell (165) to cover assy with countersunk screws (170). 2 Install cover assy (160) to upper part assy with countersunk screws (245).
(zl)
Installation of plug support assemblies (60, 90, 120) 1 Install alignment bushings (75, 105, -135) to plug support assemblies (60, 90, 120) with pan-head screws (80, 110, -140) and washers (85, 115, -145). 2 Install spacers (65, 95, -125) to plug support assemblies (60, 90,120) with countersunk screws (70, 100, -130). 3 Install plug support assemblies (60, 90, 120) to upper part assy with pan-head screws (150) and washers (155).
(zm)
Installation of sliding work table assy (35) 1 Install retainer (40) to sliding work table assy (35). 2 Install sliding work table assy (35) to upper part assy and secure with retainer (40).
(zn)
Installation of door assy (20) 1 Install door assy (20) to upper part assy with countersunk screws (25) and washers (30).
(zo)
Installation of insulated door assy (5) 1 Install insulated door assy (5) to upper part assy with countersunk screws (10) and washers (15).
(5)
Upper part assy unit G4A (refer IPC, fig 6D) (a) (b) (c) (d) (e) Install teflon (65, 70) to upper part assy. Install bottle support (110) and bolt (115) to upper part assy with pan-head screws (120). Install cover (50) to upper part assy with countersunk screws (55, 60). Install strikes (85) to upper part assy with countersunk screws (90). Install joint cover (80) to upper part assy.
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(f) (g) (h) (i)
Install cover cap (75) to upper part assy, Install upper attachment bracket (10) to upper part assy with hexagonal screws (15) and washers (20). Install work counter top (5) to upper part assy. Install drip pan assy (95) to upper part assy. 1 Install sieve (100) to drip pan assy (95) with countersunk screws (105).
(j)
Installation of ice bucket assy (25) 1 Install sieve (35) and extrusion (30) to ice bucket assy (25) with countersunk screws (40). 2 Install ice bucket assy (25) to upper part assy with countersunk screws (45).
R.
Rear Part Assemblies Unit G6, G7 And G4A (1) Rear part assy unit G6 (refer IPC, fig 7) (a) (b) (c) (d) (2) Install sealing profile (70) to rear part assy (-1). Install air grid (60) to rear part assy with countersunk screws (65). Install strike (50) to rear part assy with countersunk screws (55). Install door assy (5) to rear part assy with countersunk screws (10) and washers (15).
Rear part assy Unit G7 (refer IPC, fig 7A) (a) (b) (c) (d) Install sealing profile (70) to rear part assy (-1). Install air grid (60) to rear part assy with countersunk screws (65). Install strikes (50) to rear part assy with countersunk screws (55). Install door assy (5) to rear part assy with countersunk screws (10) and washers (15).
(3)
Rear part assy Unit G4A (refer IPC, fig 7B) (a) Install joint cover (40) to rear part assy (-1).
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(b) (c) (d) S.
Install extrusion (25) to rear part assy with pan-head screws (30) and washers (35). Install lower attachment brackets (15) to rear part assy with countersunk screws (20). Install door assy (5) to rear part assy with countersunk screws (10).
Pelmet Units G3/G4 And G6/G7 Assemblies (1) Pelmet unit G3/G4 assy (refer IPC, fig 2) (a) (b) (c) (d) Install sealing profile (505) to pelmet assy (-1). Install work light casing (125) to pelmet assy with pan-head screws (130) and washers (135). Install work light cover (140) to pelmet assy with countersunk screws (145). Installation of bar assy (490) 1 Install sealing profiles (495, 500) to bar assy (490). 2 Install bar assy (490) to pelmet assy. (e) Installation of support assemblies (470, 480) 1 Install sealing profiles (475, 485) to support assemblies (470, 480). 2 Install support assemblies (470, 480) to pelmet assy. (f) Installation of support assemblies (380, 425) 1 Install velcros (395, 440) and sealing profiles (385, 430) to support assemblies (380, 425). 2 Install supports (410, 455) and shims (420, 465) to support assy (380, 425) with pan-head screws (415, 460). 3 Install extrusions (390, 435) and sealing profiles (400, 445) to support assy (380, 425) with countersunk screws (405, 450). 4 Install support assemblies (380, 425) to pelmet assy.
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(g)
Installation of ceiling panel assemblies (270, 290, 310, 325, 340, 360) 1 Install velcros (275, 295, 315, 330, 345, 365) and sealing profiles (280, 300, 370) to ceiling panel assemblies (270, 290, 310, 325, 340, 360). 2 Install ceiling panel assemblies (270, 290, 310, 325, 340, 355) to pelmet assy. 3 Install closing caps (285, 305, 320, 335, 355, 375) to ceiling panel assemblies (270, 290, 310, 325, 340, 355).
(h)
Installation of pelmet assemblies (150, 180, 210, 240) 1 Install velcros (175, 205, 235, 265) to pelmet assemblies (150, 180, 210, 240). 2 Install brackets (155, 165, 185, 195, 215, 225, 245) to pelmet assemblies (150, 180, 210, 240) with pan-head screws (160, 170, 190, 200, 220, 260, 250, 260). 3 Install pelmet assemblies (150, 180, 210, 240) to pelmet assy.
(i)
Installation of ceiling panel assy (70) 1 Install ceiling panel assy (70) to pelmet assy with pan-head screws (115) and washers (120). 2 Install extrusion (75) to ceiling panel assy (70). 3 Install exhaust hood (80) to ceiling panel assy (70) with pan-head screws (85). 4 Installation of air screen assy (95) a Install air screen assy (95) to ceiling panel assy (70) and secure with fasteners (-110). b Install filter pad (-105) to air screen assy (95) with fasteners (-110) and retainer (-100). 5 Install sealing profile (90) to ceiling panel assy (70).
(j)
Installation of ceiling panel assemblies (40, 55) 1 Install sealing profiles (50, 65) to ceiling panel assemblies (40, 55). 2 Install extrusions (45, 60) to ceiling panel assemblies (40, 55).
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3 Install ceiling panel assemblies (40, 55) to pelmet assy. (k) Installation of ceiling panel assemblies (10, 25) 1 Install velcros (20, 35) to ceiling panel assemblies (10, 25). 2 Install extrusions (15, 30) to ceiling panel assemblies (10, 25). 3 Install ceiling panel assemblies (10, 25) to pelmet assy. (l) (2) Connect electrical system (5) to airplane supply system.
Pelmet unit G6/G7 assy (refer IPC, fig 2A) (a) (b) (c) (d) (e) Install sealing profiles (295, 300, 305) to pelmet assemblies (5, 130). Install bar (240) and spacer (275) to galley units G6 and G7 with pan-head screws (280). Install supports (255) to galley units G6 and G7 with pan-head screws (265) and washers (270). Install bars (240) to supports (255) with pan-head screws (260). Installation of ceiling panel assy (130) 1 Install sealing profiles (225, -230) to ceiling panel assy (130). 2 Install extrusions (200, -205) to extrusion (190, -185) with countersunk rivets (235). 3 Install extrusions (-175, 180, -185, 190, 195) and spacers (210, 215) to ceiling panel assy (130) with pan-head screws (220) and washers (145). 4 Install fasteners (150) to lens (160). 5 Install lamp casing (135) to ceiling panel assy (130) pan-head screws (140), washers (145) and secure with fasteners (150). 6 Installation of lens assy (155) a Install adhesive foil (165) to lens assy (130). b Install fasteners (170) to lens (160). c Install lens assy (155) to ceiling panel assy (130) and secure with fasteners (170).
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7 Install ceiling panel assy (130) to pelmet assy and secure with fasteners (250). (f) Installation of ceiling panel assy (5) 1 Install sealing profile (115) to ceiling panel assy (5). 2 Install extrusion (70) to ceiling panel assy (5). 3 Install extrusions (100, -105) to extrusion (90) with countersunk rivets (120). 4 Install extrusions (75, -80, -85, 90) and spacers (95) to ceiling panel assy (5) with pan-head screws (110) and washers (25). 5 Install fasteners (125) to lamp casings (10, 15). 6 Install lamp casings (10, 15) to ceiling panel assy (5) pan-head screws (20), washers (25) and secure with fasteners (125). 7 Installation of lens assemblies (30, 50) a Install adhesive foils (40, 60) to lens assemblies (30, 35). b Install fasteners (45, 65) to lenses (35, 50). c Install lens assemblies (35, 50) to ceiling panel assy (5) and secure with fasteners (45, 65). 8 Install spacers (245, 290) to ceiling panel assy (5) with fasteners (250). 9 Install ceiling panel assemblies (5, 130) to pelmet assy and secure with fasteners (250). 10 Connect electrical system (310) to airplane supply system. T. Galley Units G1, G2, G3, G4, G5, G6, G7, G4A, RH Closet And AFT Partition - Structure Assemblies (1) Galley unit G1 Structure assy (a) Installation of lower part assy (5) and upper part assy (10) (refer IPC, fig 4) 1 Install upper part assy (10) to lower part assy (5) with allen screws (15, 20), pan-head screws (35), special nuts (25) and washers (30).
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2 Install joint covers (525, fig 6) to structure assy (-1). 3 Install decorative materials (30, fig 3). 4 Connect electrical system (10, fig 3), water installation assy (15, fig 3) and ventilation system (20, fig 3) to structure parts and airplane supply systems. (b) (c) (d) (e) Install spacers (50) and bumpers (55) to structure assy with countersunk screws (60). Install single revolving catches (65, 80) to structure assy with pan-head screws (70, 75). Install single revolving catches (40, 45) to structure assy (-1) (refer IPC, fig 4). Install tie rods (70, -75) to upper attachment brackets (485, fig 6; 635, fig 6) with pan-head screws (90), washers (95) and pip-pins (80, -110) with securing ropes (85) (refer IPC, fig 3). Install cup holder (60) to structure assy (5) with pan-head screws (65). Install paper clip (50) to structure assy (5) with countersunk screws (55). Install mirror (45) to structure assy (5). Installation of beverage maker 1 Install beverage maker to compartment 107. (j) Installation of refrigerator 1 Install refrigerator to compartment 106 with pan-head screws (35) and washers (40). (k) Installation of steam ovens 1 Install steam ovens to compartments 104 and 105 with pan-head screws (35) and washers (40). 2 Install cover caps (575, fig 6) to structure assy (5). (2) Galley unit G2 Structure assy (a) Install extrusions (-345, -665), bumpers (515, 520), shims (525, 530, 645), guides (595) and sliding strips (640) to structure assy (-1) (refer IPC, fig 4A).
(f) (g) (h) (i)
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(b) (c) (d) (e) (f) (g) (h) (i) (j) (k)
Install extrusion (660) and shims (650, 655) to structure assy with pan-head screws (140) and washers (145). Install extrusion (625) to structure assy with countersunk screws (315). Install guides (615) to structure assy with countersunk screws (620). Install extrusion (600) to structure assy with pan-head screws (140). Install lower attachment brackets (535, 570) to structure assy with countersunk screws (305, 325), pan-head screws (540) and washers (475). Install cover (505) and air grid (560) to structure assy with countersunk screws (510). Install brackets (485, 490, -495) to structure assy with pan-head screws (500) and washers (145). Install bracket (480) to structure assy with pan-head screws (140). Install supports (465) to structure assy with hexagonal screws (470) and washers (475). Install extrusions (445) and upper attachment brackets (430) to structure assy with hexagonal screws (435), countersunk screws (460), washers (440, 455) and hexagonal nuts (450). Install single revolving catches (415, 420) to structure assy. Install single revolving catches (395, 400) and double revolving catch (425) to structure assy with pan-head screws (405, 410). Install extrusions (380, 385) to structure assy with countersunk screws (280, 390). Install spacers (365) and bumpers (360) to structure assy with countersunk screws (315). Install extrusions (330, 335, 340, 375), air grids (-350, 355) and sealing profile (370) to structure assy with pan-head screws (140) and washers (145). Install guide (320) to structure assy with countersunk screws (325). Install spacers (310) to structure assy with countersunk screws (315). Install strikes (565) to structure assy with countersunk screws (85, 390).
(l) (m) (n) (o) (p)
(q) (r) (s)
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(t) (u) (v)
Install extrusions (75) and shims (80) to structure assy with pan-head screws (140). Install work counter top (70) to structure assy. Installation of roller blind installation assy (670) 1 Install grips (690) to roller blind installation assy (670) with countersunk screws (695). 2 Install loop (685) to roller blind installation assy (670) with countersunk screws (695). 3 Installation of support assy (675) a Install fasteners (680) to support assy (675). b Install support assy (675) to roller blind installation assy (670) and secure with fasteners (680). 4 Install roller blind installation assy (670) to structure assy with panhead screws (700) and washers (705).
(w)
Installation of revolving catch assy (630) 1 Install bushings (55, fig 21A; 65, fig 21A) to support (5, fig 21A) 2 Install support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) to upper part assy with pan-head screws (710). 3 Install axle (10, fig 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) to support (5, fig 21A) with setscrew (60, fig 21A) and ball catch (40, fig 21A). 4 Install cover (25, fig 21A) to support (5, fig 21A) with countersunk screws (20, fig 21A). 5 Install knob (30, fig 21A) and washer (15, fig 21A) to axle (10, fig 21A) with slotted pin (35, fig 21A).
(x)
Installation of revolving catch assy (605) 1 Install bushing (40, fig 21) and distance bushing (25, fig 21) to support (5, fig 21). 2 Install support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) to upper part assy with pan-head screws (610).
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3 Install axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) to support (5, fig 21) with setscrew (45, fig 21) and ball catch (30, fig 21). 4 Install knob (60, fig 21) and distance bushing (20, fig 21) to axle (10, fig 21) with slotted pin (35, fig 21). (y) Installation of cover assy (575) 1 Install sealing profile (-580), sliding strip (-585) and plate (-590) to cover assy (575). 2 Install cover assy (575) to structure assy with countersunk screws (305), with pan-head screws (295) and washers (145) and. (z) Installation of cover assy (545) 1 Install sealing profile (550) and plate (555) to cover assy (545). 2 Install cover assy (545) to structure assy with pan-head screws (295) and washers (145). (za) Installation of disengaging installation assy (285) 1 Install disengaging installation assy (285) with pan-head screws (295), countersunk screws (305), bushings (300) and threaded bushings (290). (zb) Installation of sink assy (260) 1 Install sieve (-265) to sink assy (260) with pan-head screws (-270). 2 Install sink assy (260) to structure assy with pan-head screws (275) and washers (280). (zc) Installation of upper attachment assemblies (190, 225) 1 Install upper attachment assemblies (190, 225) to upper attachment brackets (430) and to extrusions (445) with hexagonal screws (195, 210, 230, 245), washers (200, 215, 235, 255) and hexagonal nuts (205, 220, 240, 250). (zd) Installation of door holder assy (150) 1 Install brackets (-160, -165) and shim (-170) to gas spring cylinder (-155) with screws (-175). 2 Install door holder assy (150) with pan-head screws (180) and washers (185).
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(ze) (zf)
Install extrusions (135) and sealing profiles (130) to structure assy. Installation of guide assemblies (90, 100, 110, -120) 1 Install sliding strips (95, 105, 115, -125) to guide assemblies (90, 100, 110, -120). 2 Install guide assemblies (90, 100, 110, -120) to structure assy with pan-head screws (140) and washers (140).
(zg)
Installation of sliding work table assemblies (50, 65) NOTE: Prior to release the pan of sliding work table, make sure, that the attachment screws have been entirely pulled downwards and a minimum space 8,0 mm (0.32) between the upper surface of the fastener and the surface of the shell is granted. These can be checked e.g. with fingertip. 1 Install retainers (55, 65) to structure assy. 2 Install sliding work table assemblies (50, 60) to structure assy and secure with retainers (55, 65).
(zh)
Installation of drawer assy (45) 1 Install rail guides (65, fig 17A) to structure assy with countersunk screws (70, fig 17A). 2 Install drawer assy (45) to stop, push arresting button and install drawer assy (45) to rail guides (65, fig 17A).
(zi)
Installation of door assemblies (25, 35) 1 Install door assemblies (25, 35) to structure assy with pan-head screws (30, 40).
(zj)
Installation of insulated folding door assemblies (5, 15) 1 Install insulated folding door assemblies (5, 15) to structure assy with pan-head screws (10, 20).
(zk)
Install tie rod (35) to upper attachment assy (190, fig 4A) with pan-head screw (65), washer (70) and pip-pin (55) with securing rope (60) (refer IPC, fig 3A). Install tie rod (35) to upper attachment assy (225, fig 4A) with hexagonal screw (40), washers (45) and hexagonal nut (50).
(zl)
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(zm)
Installation of microwave oven 1 Install microwave oven to compartment 205 with countersunk screws (75).
(3)
Galley unit G3 Structure assy (a) Install sliding strips (180, 425, 470, 475, 490, 495, 500), guides (300, 305), shims (310, 385, 420) and bumpers (485) to structure (-1) (refer IPC, fig 4B). Install guide (480) to structure assy with countersunk screws (260). Install guides (460) to structure assy with countersunk screws (465). Install strikes (450, 570) to structure assy with countersunk screws (455). Install extrusion (410) to structure assy with pan-head screws (120). Install shims (395, 400) and plate (390) to structure assy with countersunk screws (405). Install bumpers (370) and shims (575) to structure assy with pan-head screws (200). Install single revolving catches (355) to structure assy with pan-head screws (360) and hexagonal nuts (365). Install extrusions (335, 340, -345) to structure assy with pan-head screws (350). Install upper attachment brackets (315, 320) to structure assy with hexagonal screws (325) and washers (330). Install extrusions (185, 390, 395, 200) to structure assy. Install lower attachment brackets (375, 380, 415) to structure assy with countersunk screws (555), pan-head screws (560) and washers (565). Install cover (245, 250) to structure assy with countersunk screws (260), pan-head screws (255) and washers (175). Install single revolving catches (210, 215) to structure assy. Install extrusions (165) and sealing profiles (160) to structure assy with pan-head screws (170) and washers (175). Installation of drip pan assy (435) 1 Install sieve (440) to drip pan assy (435) with countersunk screws (445).
(b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p)
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2 Install drip pan assy (435) to structure assy. (q) Installation of cover assy (265) 1 Install cover assy (265) to structure assy with countersunk screws (465). 2 Install closing cap (270) to cover assy (265) with pan-head rivets (275). (r) Installation of cover assy (235) 1 Install sealing profile (240) to cover assy (235). 2 Install cover assy (235) to structure assy with countersunk screws (260), pan-head screws (255) and washers (175). (s) Installation of cover assy (220) 1 Install sealing profile (225) to cover assy (220). 2 Install plate (230) to cover assy (220). 3 Install cover assy (220) to structure assy with countersunk screws (260), pan-head screw (255) washer (175). (t) Installation of guide assy (145) 1 Install sliding strips (150) and shims (155) to guide assy (125). 2 Install shims (115) and guide assy (145) to structure assy with pan-head screws (120). 3 Install sliding strips (110, 130, 140) to guide assemblies (105, 125, 135). (u) Installation of guide assemblies (105, 125, 135) 1 Install guide assemblies (105, 125, 135) and shims (115) to structure assy with pan-head screws (120). (v) Installation of ice drawer assy (100) 1 Install and rail guides (55, fig 17) to structure assy with countersunk screws (60, fig 17). 2 Install ice drawer assy (100) to rail guides (55, fig 17) and push it over stop.
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(w)
Installation of upper attachment assy (65) 1 Install upper attachment assy (65) to structure assy with hexagonal screws (80, 85), washers (75, 95) and hexagonal nuts (70, 90).
(x)
Installation of door assemblies (5, 15, 25, 35, 45, 55) 1 Install door assemblies (5, 15, 25, 35, 45, 55) to structure assy with countersunk screws (10, 20, 30, 40, 50, 60):
(y)
Installation of door holder assy (505) 1 Install brackets (520) to retainer (510) with pan-head screws (530), washers (550) and hexagonal nuts (540). 2 Open doors (45, 55) and install door holder assy (505) to doors (45, 55) and to structure assy with countersunk screws (525), pan-head screws (545), washers (535) and spacers (515).
(z) (za) (4)
Install tie rods (185) to upper attachment assy (65) with pan-head screws (200), washers (205) and pip-pin (190) with securing ropes (195) Connect electrical system (-10), water installation assy (15) and cooling system (20) to airplane supply systems (refer IPC, fig 3B).
Galley unit G4 structure assy (a) Installation of lower part assy (5) and upper part assy (10) (refer IPC, fig 4C) 1 Install upper part assy (10) to lower part assy (5) with allen screws (15, 25) and special nuts (20). 2 Install joint covers (290 fig 6A, 295, fig 6A) to structure assy (-1). 3 Install decorative materials (35, fig 3C). 4 Connect electrical system (10, fig 3C), water installation assy (15, fig 3C), ventilation system (20, fig 3C) and cooling system (25, fig 3C) between structure parts and to airplane supply systems. (b) (c) (d) Install extrusion (105) and sealing profile (110) to structure assy with pan-head screws (115). Install bumpers (90) and spacers (95) to structure assy with countersunk screws (100). Install single revolving catches (80, 85) to structure assy.
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(e) (f) (g)
Install single revolving catches (70) to structure assy with pan-head screws (75). Install cover (30) to structure assy with countersunk screws (35, 40). Installation of roller blind installation assy (-150) 1 Install supports (175) to roller blind installation assy (-150) with pan-head screws (180) and washers (185). 2 Installation of roller blind assy (155) a Install grip (165) to roller blind assy (155) and with pan-head screws (170). b Install loop (160) to roller blind assy (155) with pan-head screws (170). c Install roller blind assy (155) with countersunk screws (190).
(h)
Installation of cover assemblies (-120, 130, 140) 1 Install sealing profiles (-125, 135, 145) to structure assy to cover assemblies (-120, 130, 140). 2 Install cover assemblies (-120, 130, 140) to structure assy with countersunk screws (35, 40).
(i)
Install tie rods (45) to upper part assemblies (50, fig 6A) with countersunk screws (60), washers (65) and pip-pins (50) with securing rope (55) (refer IPC, fig 3C). Installation of refrigerator 1 Install refrigerator to compartment 408 with pan-head screws (135) and washers (140).
(j)
(k)
Installation of beverage maker 1 Install beverage maker to compartment 407.
(l)
Installation of hot jug 1 Install hot jug to compartment 406.
(m)
Installation espresso maker 1 Install espresso maker to compartment 405.
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(n)
Installation of steam oven (refer IPC, fig 3C) 1 Install steam oven to compartment 404 with pan-head screws (135), washers (140).
(5)
Galley unit G5 Structure assy (a) Install work counter top (65), velcro (85), guides (280, 285, -290, 400, 405, 565), sliding strips (270, 430, 440, 450, 455, 490, 515, 520, 555, -560, 585, 605, 610), shims (435, -445, 460, 510, -570, 590, 615) to structure assy (-1) (refer IPC, fig 4D). Install brackets (575, -595) and extrusions (580, -600) to structure assy. Install extrusions (545) to structure assy. Install bonding clip (-540) to structure assy. Install strikes (485) to structure assy with countersunk screws (235, 550). Install cover caps (480) to structure assy. Install guides (475) to structure assy with countersunk screws (160). Install bumpers (390) and shim (395) to structure assy with countersunk screws (160). Install cover (365) to structure assy with countersunk screws (160). Install spacers (355), shims (350) and bumpers (345) to structure assy with countersunk screws (360). Install bumpers (335) to structure assy with countersunk screws (340). Install lower attachment brackets (295, 370) to structure assy with countersunk screws (300), pan-head screws (305) and washers (310). Install guides (260) and extrusion (265) to structure assy with countersunk screws (160). Install upper attachment brackets (240) to structure assy with countersunk screws (245), washers (250) and hexagonal nuts (25). Install single revolving catches (205, 225) to structure assy. Install single revolving catches (190, 195, 210, 215) to structure assy with pan-head screws (200, 220).
(b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p)
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(q) (r) (s) (t) (u) (v)
Install extrusions (165, 170, 175, 180, 185) to structure assy with countersunk screws (235). Install extrusion (155) to structure assy with countersunk screws (160). Install console (145) to structure assy with countersunk screws (150). Install spacer (135) and table holder (130) to structure assy with pan-head screws (140, 230) and washers (125). Install bottle holder (90) to structure assy with countersunk screws (95). Installation of drip pan assy (525) 1 Install sieve (-530) to drip pan assy (525) with countersunk screws (-535). 2 Install drip pan assy (525) to structure assy.
(w)
Installation of revolving catch assy (495) 1 Install bushings (55, fig 21A; 65, fig 21A) to support (5, fig 21A) 2 Install support (5, fig 21A) with bushings (55, fig 21A; 65, fig 21A) to upper part assy with countersunk screws (500). 3 Install axle (10, fig 21A), revolving catch (50, fig 21A) and retaining ring (45, fig 21A) to support (5, fig 21A) with setscrew (60, fig 21A) and ball catch (40, fig 21A). 4 Install cover (25, fig 21A) to support (5, fig 21A) with countersunk screws (20, fig 21A). 5 Install knob (30, fig 21A) and washer (15, fig 21A) to axle (10, fig 21A) with slotted pin (35, fig 21A).
(x)
Installation of revolving catch assy (465) 1 Install bushing (40, fig 21) and distance bushing (25, fig 21) to support (5, fig 21). 2 Install support (5, fig 21) with bushing (40, fig 21) and distance bushing (25, fig 21) to upper part assy with countersunk screws (470). 3 Install axle (10, fig 21), revolving catch (15, fig 21), lock washers (55, fig 21) and washer (50, fig 21) to support (5, fig 21) with setscrew (45, fig 21) and ball catch (30, fig 21).
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4 Install knob (60, fig 21) and distance bushing (20, fig 21) to axle (10, fig 21) with slotted pin (35, fig 21). (y) Installation of disengaging installation assy (410) 1 Install disengaging installation assy (410) to structure assy with countersunk screws (160), pan-head screws (420), bushings (425) and threaded bushings (415). (z) Installation of guide assy (100) 1 Install sliding strips (105) to guide assy (100). 2 Install guide assy (100), extrusions (115) and sealing profiles (110) to structure assy with pan-head screws (120) and washers (125). (za) Installation of cover assy (375) 1 Install sealing profile (385) to cover assy (375). 2 Install spacer (380) to cover assy (375). 3 Install cover assy (375) to structure assy with countersunk screws (330). (zb) Installation of cover assy (315) 1 Install sealing profile (325) to cover assy (315). 2 Install plate (320) to cover assy (315). 3 Install cover assy (315) to structure assy with countersunk screws (330). (zc) Installation of cover assy (70) 1 Install velcro (80) to cover assy (70). 2 Install closing cap (75) to cover assy (70). 3 Install cover assy (70) to structure assy. (zd) Installation of sliding work table assy (55) NOTE: Prior to release the pan of sliding work table, make sure, that the attachment screws have been entirely pulled downwards and a minimum space 8,0 mm (0.32) between the upper surface of the fastener and the surface of the shell is granted. These can be checked e.g. with fingertip. 1 Install retainer (60) to structure assy.
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2 Install sliding work table assy (55) to structure assy and secure with retainer (60). (ze) Installation of ice drawer assy (50) 1 Install rail guides (60, fig 17A) to structure assy with countersunk screws (65, fig 17A). 2 Install ice drawer assy (50) to stop, push arresting button and install ice drawer assy (50) to rail guides (60, fig 17A) in compartments 510 and 511. (zf) Installation of door assemblies (20, 35) 1 Install door assemblies (20, 35) to structure assy with countersunk screws (25, 40) and washers (30, 45). (zg) Installation of door assy (5) 1 Install door assy (5) to structure assy with pan-head screws (10) and washers (15). (zh) (zi) (zj) (zk) (6) Install wine bottle opener (55) to structure assy (5) with pan-head screws (60) and washers (65) (refer IPC, fig 3D). Install tie rods (30) to upper attachment brackets (240, fig 4D) with panhead screws (45), washers (50) and pip-pins (35) with securing rope (40). Install decorative materials (25). Connect electrical system (-10) and water installation assy (15) to airplane supply system (refer IPC, fig 3D).
Galley unit G6 Structure assy (a) Installation of lower part assy (5), upper part assy (10) and rear part assy (25) (refer IPC, fig 4E) 1 Install upper part assy (10) to lower part assy (5) with allen screws (15, 20). 2 Install AFT partition (55, fig 1) to lower part assy (5) and to upper part assy (10) with countersunk screws (20, fig 1). 3 Install rear part assy (25) to lower part assy (5) and to upper part assy (10) with countersunk screws (30, 35), pan-head screws (175) and washers (180). 4 Install joint covers (395, fig6B; 405, fig 6B) to structure assy (-1).
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5 Install decorative materials (35, fig 3E) 6 Connect electrical system (10, fig 3E), water installation assy (15, fig 3E), ventilation system (20, fig 3E) and cooling system (25. fig 3E) to structure parts and to airplane supply systems. (b) (c) (d) (e) (f) Install guides (-165, 170) to structure assy. Install cover (-185) to structure assy. Install single revolving catches (155) to structure assy with pan-head screws (160). Install single revolving catches (130, 135, 140, 145, 150) to structure assy. Installation of door assemblies (100, 115) 1 Install door assemblies (100, 115) to structure assy with countersunk screws (105, 120) and washers (110, 125). (g) Installation of insulated door assemblies (55, 85) 1 Install insulated door assemblies (55, 85) to structure assy with countersunk screws (60, 90) and washers (65, 95). (h) Installation of insulated folding door assemblies (40, 70) 1 Install insulated folding door assemblies (40, 70) to structure assy with countersunk screws (45, 75) and washers (50, 80). (i) Installation of hot jugs (refer IPC, fig 3E) 1 Install hot jugs to compartments 615, 616 and 617. (j) Installation of beverage makers 1 Install beverage makers to compartments 612, 613 and 614. (k) Installation of refrigerators 1 Install refrigerators to compartments 608, 609 and 610 with pan-head screws (85) and washers (90).
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(7)
Galley unit G7 Structure assy (a) Installation of lower part assy (5), upper part assy (10) and rear part assy (25) (refer IPC, fig 4F) 1 Install upper part assy (10) to lower part assy (5) and allen screws (15, 20). 2 Install AFT partition assy (55, fig 1) to lower part assy (5) and to upper part assy (10) with countersunk screws (70, fig 1). 3 Install rear part assy (25) to upper part assy (10) and lower part assy (5) with countersunk screws (30, 35), pan-head screws (180) and washers (40, 185). 4 Install joint covers (420, fig 6C, 430, fig 6C) to structure assy (-1). 5 Install decorative materials (35, fig 3F). 6 Connect electrical system (10, fig 3F), water installation assy (15, fig 3F), ventilation system (20, fig 3F) and cooling system (25, fig 3F) between structure parts and to airplane supply systems. (b) (c) (d) Install single revolving catches (150) to structure assy with pan-head screws (155). Install single revolving catches (135, 140, 145) to structure assy. Installation of sliding coat rod assy (160) 1 Install sliding coat rod assy (160) and spacers (175) to structure assy with countersunk screws (165, 170). (e) Installation of door assemblies (105, 120) 1 Install door assemblies (105, 120) to structure assy with countersunk screws (110, 125) and washers (115, 130). (f) Installation insulated door assemblies (60, 90) 1 Install insulated door assemblies (60, 90) to structure assy with countersunk screws (65, 95) and washers (70, 100). (g) Installation of insulated folding door assemblies (45, 75) 1 Install insulated folding door assemblies (45, 75) to structure assy with countersunk screws (50, 80) and washers (55, 85).
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(h)
Installation of steam ovens (refer IPC, fig 3F) 1 Install steam ovens to compartments 710, 711, 712, 713, 714 and 715 with pan-head screws (90).
(i)
Installation of bun warmers 1 Install bun warmers to compartments 701, 702 and 703 with countersunk screws (85).
(8)
Bar unit G4A Structure assy (a) Installation of lower part assy (5), upper part assy (10) and rear part assy (30) (refer IPC, fig 4G) 1 Install upper part assy (10) to lower part assy (5) allen screws (20, 25) and special nuts (15). 2 Install rear part assy (30) to upper part assy (10) and lower part assy (5) with countersunk screws (35) and allen screws (40). 3 Install joint covers (80, fig 6D) to structure assy. 4 Install decorative materials (25). 5 Connect electrical system (10, fig 3G) and water installation assy (15, fig 3G) between structure parts and to airplane supply systems. (b) (c) (d) Install coat rods (80) to structure assy with countersunk screws (195). Install covers (180, 185) to structure assy with countersunk screws (190). Install extrusions (-100, 105, 110, -115, -120, 125, -130, 135), sealing profiles (85, 90, 95) and shims (140, 145, -150, -155, 160, 165, -170) to structure assy with countersunk screws (175). Install bracket (45) to structure assy with countersunk screws (50). Install tie rod (55) to upper attachment bracket (10, fig 6D) with pan-head screw (70), washer (75) and pip-pin (60) with securing rope (65).
(e) (f) (9)
RH closet unit Structure assy (a) (b) Install bumpers (150) to structure assy (-1) with pan-head screws (155) and washers (160) (refer IPC, fig 4H). Install strike (115), retainer (125) and bumper (130) to structure assy with countersunk screws (120, 165).
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(c) (d) (e) (f) (g) (h) (i) (j) (k) (l)
Install strike (115) to structure assy with countersunk screws (120). Install lower attachment brackets (105) to structure assy with countersunk screws (110). Install extrusions (90, -95, -100, 135, 140, 145) to structure assy. Install access cover (85) to structure assy with countersunk screws (85). Install covers (70) to structure assy with countersunk screws (75). Install lamp casing (60) to structure assy with countersunk screws (65). Install covers (55) to structure assy with countersunk screws (30). Install upper attachment brackets (35) to structure assy with hexagonal screws (40), washers (45) and hexagonal nuts (50). Install coat rod (25) to structure assy with countersunk screws (30). Installation of roller blind assy (15) 1 Install extrusions (90, -95, -100, 135, 140, 145) to structure assy with countersunk screws (20). 2 Install roller blind (5, fig 16) to extrusions (90, -95, -100, 135, 140, 145). 3 Install plate (170) to structure assy. 4 Install bumper (150) to roller blind (5, fig 16) with pan-head screws (155) and washers (160). 5 Close roller blind (5, fig 16).
(m)
Installation of folding bottom assy (5) 1 Install folding bottom assy (5) to structure assy with pan-head screws (10).
(n) (o) (10)
Install decorative materials (20) (refer IPC, fig 3H). Connect electrical system (-10) to airplane supply system.
RH Coat closet door 2 Structure assy (a) (b) Install teflon (85) to structure assy (-1) (refer IPC, fig 4J). Install strike (125) to structure assy with countersunk screws (130).
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(c) (d) (e) (f) (g) (h) (i) (j) (k)
Install access cover (120) to structure assy. Install upper attachment bracket (105) to structure assy with hexagonal screws (110) and washers (115). Install extrusion (90) to structure assy with pan-head screws (95) and washers (100). Install fitting (75) to structure assy with countersunk screws (80). Install covers (-35, 40) to structure assy with countersunk screws (45). Install extrusion (25) to structure assy with countersunk screws (30). Install coat rod (15) to structure assy with countersunk screws (20). Install tie rod (50) to upper attachment bracket (105) with pan-head screw (65), washer (70) and pip-pin (55) with securing rope (60). Installation of door assy (5) 1 Install door assy (5) to structure assy with countersunk screws (10).
(l) (m) (11)
Install decorative materials (20) (refer IPC, fig 3J). Connect electrical system (-10) to airplane supply system.
AFT Partition assy (a) (b) (c) (d) (e) (f) (g) Install cover (195) to structure assy (-1) with countersunk screws (115) (refer IPC, fig 4K). Install sleeves (180), hoses (185), insulating hoses (190) and T-fitting (160) to structure assy with clamps (175). Install supports (155) and clamps (165, 170, 175) to structure assy with pan-head screws (145) and washers (130). Install air boxes (140) to structure assy with pan-head screws (145) and washers (130). Install extrusion (120, 135) to structure assy with pan-head screws (125) and washers (130). Install air grid (45) to structure assy with countersunk screws (150). Installation of retainer assemblies (-50, -70, -90) 1 Install sealing profiles (110) to retainers (55, 75, 95).
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2 Install extrusions (60, 80, 100) to retainers with countersunk screws (65, 85, 105). 3 Install retainer assemblies (-50, -70, -90) to structure assy with pan-head screws (145) and washers (130). (h) Installation of access flap assy (5) 1 Install cover (45), perforated plate (15), hinge (20), bumpers (25) and spring (30) to access flap assy with fasteners (10) and rivets (35). 2 Install access flap assy (5) and secure with fasteners (10). (i) Installation of decorative materials (-15) (refer IPC, fig 3K) 1 Install decorative materials (20). (j) U. Connect electrical system (10) to airplane supply system.
Decorative Materials - Unit G1, G2, G3, G4, G5, G6, G7, G4A, RH Closet And Door 2 (1) Decorative materials - Unit G1 (refer IPC, fig 13) (a) (b) (c) (d) (e) (f) (2) Install kick strip (30), sliding strips (100, 105, 110, 115, 130, 135), shims (80, 120, 125) and decorative materials (140). Install extrusions (55, 70), metal sheets (85, 90), sealing profile (95), shims (75, 80) and decor panel (5) with countersunk screws (20, 60). Install decorative strip (65) to extrusion (55). Install end parts (45) and protecting strip (35) with pan-head screws (50). Install filling strip (40) to protecting strip (35). Install support (25) and pelmet (10) with countersunk screws (15, 20).
Decorative materials - Unit G2 (refer IPC, fig 13A) (a) (b) Install kick strips (100, 105), sliding strips (110, 115, 120) and decorative materials (125). Installation of decor panel assemblies (5, 15, 25) 1 Install sealing profiles (10, 20, 30) to decor panel assemblies (5, 15, 25).
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2 Install extrusions (35, 40, 55, 60), spacers (45) and decor panel assemblies (5, 15, 25) with countersunk screws (50, 65). (c) (d) (e) (f) (3) Install end parts (90) and protecting strips (80) with pan-head screws (95). Install filling strips (85) to protecting strips (80). Install decorative strips (70) to extrusions (35, 40, 55, 60). Install pelmet (75).
Decorative materials - Unit G3 (refer IPC, fig 13B) (a) (b) (c) Install kick strip (80) and decorative materials (95, 100, 105). Install extrusion (90) and shim (85). Installation of decor panel assemblies (5, 40) 1 Install kick strips (10, 45) and sealing profiles (35, 70) to decor panel assemblies (5, 40). 2 Install end parts (25, 60) and protecting strips (15, 50) with pan-head screws (30, 65). 3 Install filling strips (20, 55) to protecting strips (15, 50). 4 Install decor panel assemblies (5, 40) with countersunk screws (75).
(4)
Decorative materials - Unit G4 (refer IPC, fig 13C) (a) (b) Install kick strip (75), adhesive tapes (80) and decorative materials (-85, 90, 95, 100). Install decor panel assy (5) 1 Install kick strip (10) to decor panel assy (5). 2 Install decor panel assy (5). (c) Installation of decor panel assemblies (15, 60) 1 Install kick strips (20, -65) and sealing profiles (25, -70) to decor panel assemblies (15, 60). 2 Install end parts (40) and protecting strips (30) with pan-head screws (45). 3 Install filling strips (35) to protecting strips (30).
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4 Install decor panel assemblies (15, 60) with countersunk screws (50, 55). (5) Decorative materials - Unit G5 (refer IPC, fig 13D) (a) (b) (c) Install kick strips (95, -100), sliding strips (120, 125, 130, 150), sealing profiles (140, 145) and decorative materials (155, 160, 165). Install paper clip (135) with countersunk screws (60). Installation of cover assy (105) 1 Install sealing profile (110) to cover assy (105). (d) (e) (f) (g) (h) (6) Install extrusions (20, 40, 45, 50, 55), spacers (25) and decor panels (5, 10, 15) with countersunk screws (30, 60). Install decorative strips (35, 65) to extrusions (20, 40, 45, 50, 55). Install mirror (115). Install end parts (80) and protecting strips (70) with pan-head screws (85) and washers (90). Install filling strips (75) to protecting strips (70).
Decorative materials - Unit G6 (refer IPC, fig 13E) (a) Install sliding strips (70, 75, 80, 85, 90, 95, -100, 105, 110, 115, 120, 125), shims (130, 135, 140, 145), teflons (150), foams (155) and decorative materials (160, 165). Installation of decorative panel assy (5) 1 Install sealing profiles (10, 15) to decorative panel assy (5). 2 Install extrusions (40, 60), spacers (45) and decorative panel assy (5) with countersunk screws (50). (c) (d) Install decorative panel (20) with pan-head screws (25, 30) and washers (35). Install decorative strips (55, 65) to extrusions (40, 60).
(b)
(7)
Decorative materials - Unit G7 (refer IPC, fig 13F) (a) Install sliding strips (70, 75, 80, 85, 90, 95, 100, -105), shims (110), foam (120) and decorative materials (125, 130).
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(b)
Installation of decorative panel assy (5) 1 Install sealing profiles (10, 15) to decorative panel assy (5). 2 Install extrusions (40, 60), spacers (45) and decorative panel assy (5) with countersunk screws (50).
(c) (d) (e) (8)
Install decorative panel (20) with pan-head screws (25, 30) and washers (35). Install mirror (115). Install decorative strips (55, 65) to extrusions (40, 60).
Decorative materials - Unit G4A (refer IPC, fig 13G) (a) (b) Install kick strips (20, 25) and decorative materials (30, 35, 40, 45). Install pelmet (5) with countersunk screws (10, 15).
(9)
Decorative materials - RH Closet (refer IPC, fig 13H) (a) (b) (c) Install kick strips (5, 10, 15), foam plates (40, -45, 50) and decorative materials (105, 110). Install extrusions (25), sealing profiles (20) and shims (30) with countersunk screws (35). Installation of pelmet complete assy (-55) 1 Install sealing profiles (80) to complete pelmet assy (-55). 2 Installation of pelmet assy (60) a Install support (70) and velcros (75, 77) to pelmet assy (60) with pan-head screws (85) and washers (90). b Install panel (65) to pelmet assy (60). c Install pelmet assy (60) with countersunk screws (95, 100).
(10)
Decorative materials - Door 2 (refer IPC, fig 13J) (a) (b) Install kick strips (20) and decorative materials (85, 90). Install extrusions (65) and sealing profile (35) with countersunk screws (70).
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(c) (d)
Install extrusions (50, -55, 60), sealing profiles (25, 30) and shims (40, 45) with countersunk screws (75). Installation of pelmet assy (5) 1 Install sealing profile (10) to pelmet assy (5) with countersunk screws (15). 2 Install pelmet assy (5) with countersunk screws (80).
3.
STORAGE INSTRUCTIONS A. B. Tag units with overhaul data. Check that units are thoroughly clean. Cap all open plumbing and drain lines to prevent entrance of foreign material. Check that water system is completely free of moisture. Place desiccant bags inside of each galley unit. Enclose entire unit and/or equipment in a strong, durable plastic vapor barrier covering. Seal plastic with heating iron. Store each unit securely on a rigid floor pallet at an ambient temperature between 5C to 30C (40F to 86F). Refer to "Temperature Protective Coatings" and "Protection, Storage and Handling of Airplane Components" in airplane manufacturer's overhaul manual.
C. D.
E.
F.
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FITS AND CLEARANCES
1.
GENERAL A. No special fits and clearances other than specified are necessary for proper installation of the galley unit parts, subassemblies and assemblies. Torque Values Of Revolving Catch Attachment Screws Required torque values -MA- for attachment screws of revolving catches are as follows:
B.
SCREW Pan-Head Screw Pan-Head Screw Countersunk Screw
THREAD 1/4"-28UNF-3A 5/16"-24UNF-3A 1/2"-20UNF-3A TORQUE VALUES OF ATTACHMENT SCREWS FIGURE 801
TORQUE MA mN lbsinch 3.0 26.55 3.5 30.98 25.0 221.27
C.
Torque Values Of Attachment Fittings Required torque values -MT- for attachment fittings of the galley units are as follows:
FITTING Hexagonal Hexagonal Hexagonal Straining
Screw Screw Screw Screw
PART NUMBER NAS6606NAS6604NAS1096-3-8 40191-13 TORQUE VALUES OF ATTACHMENT FITTINGS FIGURE 802
TORQUE Mt mN lbsinch 35.31 312.52 9.81 86.83 4.41 39.03 35.31 312.52
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801 29/07
D.
Revolving Catches Required min. and max. torque values -Mt- for revolving catches used in the galley units are as follows: NOTE: In case the torque values taken are beyond the min. or max. values, the revolving catch must be replaced. PART NUMBER OF REVOLVING CATCH 0-132-001700000 0-132-001800000 0-132-002300000 0-132-002400000 0-132-002700000 0-132-002800000 0-132-003600000 0-132-003700000 0-132-004200000 0-132-004300000 0-132-004600000 0-132-004700000 DIM. OF REVOLV.CATCH length width depth mm mm mm (inch) (inch) (inch) 30.0 12.5 17.0 (1.18) (0.49) (0.67) 30.0 12.5 17.0 (1.18) (0.49) (0.67) 54.0 28.0 26.7 (2.13) (1.10) (1.05) 54.0 28.0 26.7 (2.13) (1.10) (1.05) 100.0 12.5 17.0 (3.94) (0.49) (0.67) 60.0 12.5 17.0 (2.36) (0.49) (0.67) 75.0 12.5 17.0 (2.95) (0.49) (0.67) 75.0 12.5 17.0 (2.95) (0.49) (0.67) 70.0 20.0 23.0 (2.76) (0.79) (0.91) 70.0 20.0 23.0 (2.76) (0.79) (0.91) 141.0 28.0 26.7 (5.55) (1.10) (1.05) 141.0 28.0 26.7 (5.55) (1.10) (1.05) -Mtmin. max. mN mN (lbsin) (lbsin) 0.23 0.28 (2.03) (2.48) 0.23 0.28 (2.03) (2.48) 0.80 0.90 (7.08) (7.97) 0.80 0.90 (7.08) (7.97) 0.23 0.28 (2.03) (2.48) 0.23 0.28 (2.03) (2.48) 0.23 0.28 (2.03) (2.48) 0.23 0.28 (2.03) (2.48) 0.10 0.40 (0.88) (3.54) 0.10 0.40 (0.88) (3.54) 0.80 0.90 (7.08) (7.97) 0.80 0.90 (7.08) (7.97) PART NUMBER OF ADAPTER
5035-02-0085A 5035-02-0085A 5035-02-0085D 5035-02-0085D 5035-02-0085A 5035-02-0085A 5035-02-0085A 5035-02-0085A 5035-02-0085B 5035-02-0085B 5035-02-0085D 5035-02-0085D
TORQUE VALUES OF REVOLVING CATCHES FIGURE 803
25-05-04
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802 29/07
E.
Location Of Revolving Catches
PART NUMBER 0-132-001700000
THREAD 1/4"-28UNF-3A
0-132-001800000
1/4"-28UNF-3A
0-132-002300000
1/2"-20UNF-3A
0-132-002400000
1/2"-20UNF-3A
0-132-002700000 0-132-002800000 0-132-003600000 0-132-003700000 0-132-004200000 0-132-004600000 0-132-004700000
1/4"-28UNF-3A 1/4"-28UNF-3A 1/4"-28UNF-3A 1/4"-28UNF-3A 5/16"-24UNF-3A 1/2"-20UNF-3A 1/2"-20UNF-3A
FIG 4 4 4 4 4 19 19 19 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 4 5 4 5 4 4 4 4
IPC, A D E F A B A B C D A B C E F A B C D E F D A D E D D D E E -
ITEM 65 395 190 155 150 70 70 70 80 400 355 70 195 40 415 210 80 130 135 45 420 215 85 205 135 140 160 425 150 140 150 210 145 145 150
LOCATION OF REVOLVING CATCHES FIGURE 804
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803 29/07
25-05-04
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804 29/07
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1.
SPECIAL TOOLS NOTE: Equivalent substitutes may be used for listed items. A. Taking the torque values of revolving catches. (1) Torque screwdriver (a) (b) (c) Measuring range: 0 to 0.98 mN (8.68 lbsinch) Part NO.: 2640 Supplier: WALTER CARL GMBH UND CO KG POSTFACH 150244 42340 WUPPERTAL GERMANY
(2)
Adapters (a) The correct adapter size for revolving catch can be determined by referring to fig 803.
(b) For adapter sizes refer to fig 901. 2. FIXTURES AND EQUIPMENT A. No special fixtures and equipment are required for overhaul of the galley units.
25-05-04
PAGE NOV
901 29/07
Torque Screwdriver Shaft 6mm (1/4") hexagonal
Nylon-Material Dia ca. 60 mm (2.35 inch)
* NOTE:
This cutout for PN 5035-02-0085A only. DIMENSIONS B mm inch 11.0 0.43 14.0 0.55 18.0 0.71
PART NUMBER OF ADAPTER 5035-02-0085A 5035-02-0085B 5035-02-0085D
A mm inch 15.5 0.61 20.0 0.78 29.0 1.14
C mm inch 15.5 * 0.61 -------------
ADAPTER FOR TORQUE SCREWDRIVER FIGURE 901
25-05-04
PAGE NOV
902 29/07

1099L CMM 25-05-04

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SELL manual

SELL GMBH 35745 HERBORN - GERMANY

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY SYSTEM PN 1099L00A00000

ORIGINAL ISSUE NOV 29/07

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SERVICE BULLETIN LIST

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PAGE FRONT PAGE FP 1 FP 2

NOV 29/07 NOV 29/07

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

LIST OF EFFECTIVE PAGES PAGE DATE

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

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COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

DESCRIPTION AND OPERATION

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G1 FIGURE 1

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G2 FIGURE 2

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G3 FIGURE 3

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

301A/B, 302A/B 303, 304 305 306, 307, 308

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G4 FIGURE 4

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G5 FIGURE 5

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G6 FIGURE 6

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G7 FIGURE 7

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

GALLEY UNIT G4A FIGURE 8

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

RH CLOSET UNIT FIGURE 9

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

1R01 1R02 1R03

COMPONENT MAINTENANCE MANUAL GALLEY BASIC PN 1099L

RH COAT CLOSET UNIT FIGURE 10