COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED …manuals.amerijet.com/digidoc/AsIs/public/Mx... · A. This manual is written to the ATA specification 100. B. The manual describes

DASELL Cabin Interior GMBH HEIN-SASS-WEG 41 21129 HAMBURG

GERMANY Vendor Code C5270

COMPONENT MAINTENANCE MANUAL WITH

ILLUSTRATED PARTS LIST

LAVATORY

B225401001-000

SEP 23/09 ORIGINAL ISSUE SEP 23/09 25-41-01

Mantra: 371-25-41-C4736, Rev: -, PRE-RELEASED

COMPONENT MAINTENANCE MANUAL LAVATORY BASIC PN B225401001-000

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RECORD OF REVISION

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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RECORD OF TEMPORARY REVISION

TEMPORARY REV.-NO

PAGE NUMBER ISSUE DATE BY DATE REMOVED

BY

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SERVICE BULLETIN LIST Service Service Bulletin Incorporated Bulletin Incorporated

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LIST OF EFFECTIVE PAGES PAGE DATE PAGE DATE PAGE DATE

FRONT PAGE DISASSEMBLY 620 SEP 23/09 FP1 SEP 23/09 301 SEP 23/09 621 SEP 23/09 FP2 SEP 23/09 302 SEP 23/09 622 SEP 23/09 303 SEP 23/09 623 SEP 23/09 RECORD OF REVISION 304 SEP 23/09 624 SEP 23/09 R/R 1 SEP 23/09 305 SEP 23/09 625 SEP 23/09 R/R 2 SEP 23/09 306 SEP 23/09 626 SEP 23/09 307 SEP 23/09 RECORD OF TEMPORARY REVISION 308 SEP 23/09 ASSEMBLY RTR 1 SEP 23/09 309 SEP 23/09 701 SEP 23/09 RTR 2 SEP 23/09 310 SEP 23/09 702 SEP 23/09 311 SEP 23/09 703 SEP 23/09 SERVICE BULLETIN LIST 312 SEP 23/09 704 SEP 23/09 SBL 1 SEP 23/09 313 SEP 23/09 705 SEP 23/09 SBL 2 SEP 23/09 314 SEP 23/09 706 SEP 23/09 707 SEP 23/09 LIST OF EFFECTIVE PAGES CLEANING 708 SEP 23/09 LEP 1 SEP 23/09 401 SEP 23/09 709 SEP 23/09 LEP 2 SEP 23/09 402 SEP 23/09 710 SEP 23/09 711 SEP 23/09 CHECK 712 SEP 23/09 501 SEP 23/09 713 SEP 23/09 LIST OF MATERIALS 502 SEP 23/09 714 SEP 23/09 LOM 1 SEP 23/09 503 SEP 23/09 LOM 2 SEP 23/09 504 SEP 23/09 INTRODUCTION LOM 3 SEP 23/09 IPL 1 SEP 23/09 LOM 4 SEP 23/09 REPAIR IPL 2 SEP 23/09 601 SEP 23/09 IPL 3 SEP 23/09 TABLE OF CONTENTS 602 SEP 23/09 IPL 4 SEP 23/09 T/C 1 SEP 23/09 603 SEP 23/09 T/C 2 SEP 23/09 604 SEP 23/09 VENDOR CODES 605 SEP 23/09 VCODE 1 SEP 23/09 INTRODUCTION 606 SEP 23/09 VCODE 2 SEP 23/09 INT 1 SEP 23/09 607 SEP 23/09 VCODE 3 SEP 23/09 INT 2 SEP 23/09 608 SEP 23/09 VCODE 4 SEP 23/09 609 SEP 23/09 DESCRIPTION AND OPERATION 610 SEP 23/09 NUMERICAL PARTS LIST 1 SEP 23/09 611 SEP 23/09 INDEX/ALPHA 2 SEP 23/09 612 SEP 23/09 NI/ALPHA 1 SEP 23/09 3 SEP 23/09 613 SEP 23/09 NI/ALPHA 2 SEP 23/09 4 SEP 23/09 614 SEP 23/09 NI/ALPHA 3 SEP 23/09 5 SEP 23/09 615 SEP 23/09 NI/ALPHA 4 SEP 23/09 6 SEP 23/09 616 SEP 23/09 NI/ALPHA 5 SEP 23/09 7 SEP 23/09 617 SEP 23/09 NI/ALPHA 6 SEP 23/09 8 SEP 23/09 618 SEP 23/09 NI/ALPHA 7 SEP 23/09 619 SEP 23/09 NI/ALPHA 8 SEP 23/09

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LIST OF EFFECTIVE PAGES PAGE DATE PAGE DATE PAGE DATE

NI/ALPHA 9 SEP 23/09 12 - 0 SEP 23/09 NI/ALPHA 10 SEP 23/09 12 - 1 SEP 23/09 NI/ALPHA 11 SEP 23/09 12 - 2 SEP 23/09 NI/ALPHA 12 SEP 23/09 12 - 3 SEP 23/09 13 - 0 SEP 23/09 NUMERICAL PARTS LIST 13 - 1 SEP 23/09 INDEX/NUMERIC 14 - 0 SEP 23/09 NI/NUM 1 SEP 23/09 14 - 1 SEP 23/09 NI/NUM 2 SEP 23/09 15 - 0 SEP 23/09 15 - 1 SEP 23/09 ILLUSTRATED PARTS LIST 15 - 2 SEP 23/09 0 - SEP 23/09 15 - 3 SEP 23/09 1 - 0 SEP 23/09 16 - 0 SEP 23/09 1 - 1 SEP 23/09 16 - 1 SEP 23/09 2 - 0 SEP 23/09 2 - 1 SEP 23/09 3 - 0 SEP 23/09 3 - 1 SEP 23/09 4 - 0 SEP 23/09 4 - 1 SEP 23/09 5 - 0 SEP 23/09 5 - 1 SEP 23/09 6 - 0 SEP 23/09 6 - 1 SEP 23/09 6 - 2 SEP 23/09 6 - 3 SEP 23/09 7 - 0 SEP 23/09 7 - 1 SEP 23/09 8 - 0 SEP 23/09 8 - 1 SEP 23/09 8 - 2 SEP 23/09 8 - 3 SEP 23/09 8 - 4 SEP 23/09 8 - 5 SEP 23/09 9 - 0 SEP 23/09 9 - 1 SEP 23/09 9 - 2 SEP 23/09 9 - 3 SEP 23/09 10 - 0 SEP 23/09 10 - 1 SEP 23/09 11 - 0 SEP 23/09 11 - 1 SEP 23/09 11 - 2 SEP 23/09 11 - 3 SEP 23/09

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LIST OF MATERIALS NOTE: Equivalent substitutes may be used for the listed items. NOTE: For the supplier's name and address refer to the chapter INTRODUCTION.

USE T D C C R A

MATERIAL DESIGNATION SUPPLIER'S CODE E I L H E S NO. AND S S E E P S SPECIFICATION T A A C A E I S N K I M N S I R B G E N L M G Y B L Y

05-033 GLASSCLOTH 91111 D2436

x

05-035 RIGID FOAM SHEET C3346

x

05-056 GLASSCLOTH 92110 D2436

x

05-057 MICROBALLOONS 2D097

x

05-109 Laminate AIRVOLT 53370

x

05-531 Solder QQ-S-571 Local purchase 75297

x

07-012 Lacquer ALEXIT 5018 D2603

x

08-001C Adhesive ARALDITE LY560 Hardener HY560

F4364 4D163

x

08-017A Adhesive EC-2216-B/A

F0347 26066

x

08-025 Adhesive

EC-3532 B/A D2607 F0347 K8767 26066

x

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USE T D C C R A


08-025B Adhesive

X

08-026

Adhesive ELASTOSIL E43

D2650 0DF77

x

08-036

Polyester Filler DAN-1090

D8357 x

08-048 Adhesive Loctite 932

D2607 F6033 K0548 05972

x

08-082

Adhesive film DAN 1211-01

D2607 F0347 26066

x

08-553

Adhesive FASTBOND 10

04963 x

11-003 TT-M-261 F0107 x x x 11-010 Isopropyl alcohol Local purchase x x AIR 3660 F1858

F3528 20638

11-016

Polishing Cleaner

0K209 x

11-520 Solvent Ethyl alcohol MIL-A-6091

Local purchase x

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USE T D C C R A


11-583

Solvent Acetone DCEA 607

Local purchase x

13-003 Chemical conversion F2865 x Coating

ALODINE 1000 or 1500 84063

14-001 Disinfectant Local purchase x AMS 1475 16-003 Coating NYCOTE 7-11 05803 x 16-046 Primer D2603 x ALEXIT FST 414-12 92310 16-047 Paint

ALEXIT FST 404-12 D2603 92310

x

Abrasive paper 200-400

grade of grain Local purchase x

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TABLE OF CONTENTS PAGE DESCRIPTION AND OPERATION ..........................................................1 UNASSIGNED .......................................................................101 UNASSIGNED .......................................................................201 DISASSEMBLY ......................................................................301 CLEANING .........................................................................401 CHECK ............................................................................501 REPAIR ...........................................................................601 ASSEMBLY .........................................................................701 UNASSIGNED .......................................................................801 UNASSIGNED .......................................................................901 ILLUSTRATED PARTS LIST......................................................... IPL 1

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INTRODUCTION 1. GENERAL A. This manual is written to the ATA specification 100. B. The manual describes maintenance on the component in a workshop. It does not describe maintenance on the component when it is installed in the aircraft. C. This manual contains: - technical data of the component, - maintenance and the repair procedure for the component. D. The data and the figures of the component are given in the separate IPC. E. We verified the DISASSEMBLY and ASSEMBLY procedure by simulation. F. The lavatories are referred to as the component in this manual. 2. MANUFACTURING The lavatories are made by: DASELL CABIN INTERIOR GMBH Hein-Sass-Weg 41 21129 HAMBURG Germany Telephone: +49 40 74314-194 Telefax : +49 40 74314-163 e-mail: [email protected] 3. Revision Service A. We make revisions for this manual when necessary. B. The related SB's are shown in the SERVICE BULLETIN LIST.

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4. ABBREVIATIONS Abbreviations used are as follows: ASSY Assembly ATA Air Transport Association CMM Component Maintenance Manual CMS Component Maintenance Sheet FIG Figure IPC Illustrated Parts Catalog IPL Illustrated Parts List LH Left Hand NO. Number NTF Non Textile Floor PA Poly-Amide PC Poly-Carbonate PN Part Number PSU Passenger Service Unit PU Poly-Urethane PVC Poly-Venyl-Chloride PVF Poly-Venyl-Foam RH Right Hand RTS Return to Seat SB Service Bulletin TDS Technical Data Sheet

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DESCRIPTION AND OPERATION 1. GENERAL A. The electrical system supplies the electrically operated equipment with power. B. The potable water tank supplies water to the lavatory. C. The drainage piping has a connection to the inflight drainage system. D. The lavatory is equipped with a recirculating toilet module. E. The lavatory has a folding door. F. Subcomponents (1) For description and operation of these subcomponents refer to the supplier's manuals: Subcomponent Vendor Code CMM/CMS/TDS-Number Toilet module MOMOGRAM SYSTEMS (29780) 38-33-13 Water tank ADAMS RITE AEROSPACE (80477) 38-10-67 Fire extinguisher FIRST TECHNOLOGY FIRE & SAFETY LTD (U3061) 26-25-36 Drain assembly EVAC GmbH (C5790) 38-31-14 Drain valve EATON AEROSPACE LTD. (K2523) 38-30-30 Timer assembly MONOGRAM SYSTEMS (29780) 38-33-13

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G. Dimensions and Weights (1) Dimensions (a) Lavatory B225401001-000 HEIGHT = 2117.58 MM; (83.37 IN) WIDTH = 752.44 MM; (29.62 IN) DEPTH = 1266.8 MM; (49.87 IN) (2) Weights The correct lavatory weight depends on the lavatory weight and the weight of the equipment which is installed. (a) Lavatory B225401001-000

1 The basic weight is 84 KG 2 The maximum weight is 125 KG 2. Description A. The lavatory has: (1) A casing, which is attached with screws (2) A rear wall which is attached with screws. (3) A folding door assy (4) A recirculating toilet module (5) A water tank (6) A washbasin (7) A fire extinguisher (8) A waste compartment (9) A handle B. For installation, the lavatory has lower attachment fittings and tie rod assemblies. C. The lavatory has a floor pan, which is attached with screws. D. The toilet flush system is connected to a vacuum system.

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E. The lavatory has a casing and a door assy which is made of a light weight material. F. The casing has sandwich panels made of honeycomb core with fiberglass coverplates 10 mm (0.39 in.) thick and/or 25 mm (0.984 in.) thick. G. Special loaded areas e. g. sandwich borders and attachment points are filled with aluminum or nylon fillers. H. The sandwich panels of the casing are bonded. J. The sandwich panels have decorative material or are painted.

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Lavatory B225401001-000

Figure 1

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3. Operation A. Folding Door Assembly (1) You can lock the folding door assembly by a latch in the lavatory. (2) When the folding door is closed and locked, a micro switch operates the TOILET OCCUPIED sign. B. Fire extinguisher (1) If there is a fire, the fire extinguishers discharges into the waste container

compartment. (2) The fire extinguishers operates automatically at an environmental temperature of

70°C (158°F).

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Wiring and Electrical Equipment Lavatory B225401001-000

Figure 2

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Wiring Diagram Lavatory PN B225401001-000

Figure 3 Sheet 1 of 2

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Wiring Diagram

Lavatory PN B225401001-000 Figure 3 Sheet 2 of 2

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D I S A S S E M B L Y 1. GENERAL A. This section is about the disassembly of the lavatory. It tells you how to remove the parts of the lavatory. B. The key index numbers you find in the exploded view illustration of the chapter ILLUSTRATED PARTS LIST. C. If the paragraph refers to one figure, only the item number is given in the brackets. If the paragraph refers to more than one figure, the figure number and the item number are given in the brackets. D. For replacement of damaged inserts and other bonded parts refer to REPAIR. 2. EQUIPMENT AND MATERIALS None 3. LIST OF PROCEDURE A. Removal of the Lavatory Attachment B. Removal and Disassembly of the Pelmet C. Removal of the Rear Wall D. Removal of the Lavatory Housing 2 E. Removal of the Lavatory Housing 3 F. Removal of the Bi-Folding Door Assy G. Disassembly of the Bi-Folding Door Assy H. Removal of the Toilet Unit and of the Toilet Shroud J. Removal of the Floor Pan K. Removal and Disassembly of the Washstand Unit L. Removal and Disassembly of the Waste Bin, the Waste Chute and the Fire Extinguisher

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M. Disassembly of the Ventilation System N. Disassembly of the Water System P. Disassembly of the Electrical System Q. Disassembly of the Cable Loom 3. LAVATORY - DISASSEMBLY NOTE: For the illustrations and the item numbers refer the chapter ILLUSTRATED PARTS LIST. A. Removal of the Lavatory Attachment (Refer IPL, Fig 2) (1) Remove the quick release pin (45) from the tie rod assy (5). (2) Remove the quick release pin (50) with the lanyard (55) and the tie rod assy (5) from the fitting (40). (3) Removal of the tie rod assy (5) (a) Remove the rod end (10), the lock washer (30) and the hexagonal nut (20) from the tie rod (35). (b) Remove the forc joint (15) and the hexagonal nut (25) from the tie rod (35). (4) Remove the hexagonal screws (60, 65), the washers (70) and the fitting (40) with

the lanyard (55) from the the lavatory structure. (5) Remove the screws and the eccentrical bushings (75, 80, 85 90) from the lavatory structure. B. Removal and Disassembly of the Pelmet (Refer IPL, Fig 3) (1) Remove the hexagonal screws (20), the washers (25), the fasteners (45) and the pelmet assy (5) from the angle assemblies (30). (2) Remove the hexagonal screws (20), the washers (25) and the angle assemblies (25). (3) Pelmet assy (5) (a) Remove the countersunk screws (15) and the spacers (10) from the pelmet assy (5).

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(4) Angle assy (30) (a) Remove the spring clip (40) from the angle (35). C. Removal of the Rear Wall (Refer IPL, Fig 4) (1) Remove the countersunk screws (20, 55), the hexagonal screws (40), the washers (35, 45) and the rear wall assy (5) from the lavatory structure. (2) Remove the countersunk screws (20) and the plates (15) from the rear wall assy (5). (3) Remove the hexagonal screws (30), the washers (35) and the angles (25) from the rear wall assy (5)). (4) Remove the bumper (50) from the rear wall assy (5). D. Removal of the Lavatory Housing 2 (Refer IPL, Fig 5) (1) Removal of the housing assy (5) (a) Remove the countersunk screws (40) and the ceiling (35) from the side wall assy (10). (2) Removal of the side wall assy (10) (a) Remove the countersunk screws (30) and the lower attachment bracket (25) from the side wall assy (10). (3) Removal of the handle assy (45) (a) Remove the security pins (55) from the handle assy (45). (b) Remove the handle assy (45) from the side wall assy. (c) Remove the special screws (50) and the special washers (60) from the side wall assy. E. Removal of the Lavatory Housing 3 (Refer IPL, Fig 6) (1) Remove the countersunk screws (170), the washers (135) and the mirror (165) from the lavatory housing 3 (-1). (2) Remove the water tank (145) from the brackets (150, 155).

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(3) Remove the countersunk screws (160), the washers (80) and the brackets (150, 155) from the lavatory housing 3. (4) Removal of the info signs cover assy (85) (a) Remove the hexagonal screws (125), the washers (135), the clip nuts (140) and the info signs cover assy (85) from the angles (120). (b) Use oxygen sign (100) 1 Remove the placard (105) from the use oxygen sign (100). 2 Remove the use oxygen sign (100) from the frame (95). (c) RTS-sign (110) 1 Remove the placard (115) from the RTS-sign (110). 2 Remove the RTS-sign (110) from the frame (95). (d) Remove the frames (95) from the info signs cover (90). (5) Remove the countersunk screws (130) and the angles (120) from the lavatory housing 3. (6) Remove the quick release pin (200) and the roller (180) from the bracket (185). (7) Remove the hexagonal screws (195), the washers (80), the bracket (185) and the block (190) from the lavatory housing 3. (8) Removal of the jamp assy (30) (a) Remove the caps (50) from the jamp assy (30). (b) Remove the hexagonal screws (75), the washers (80) and the jamp assy (30) from the side wall. (c) Remove the countersunk screw (175) and the jamp assy (30) from the lavatory structure. (d) Remove the countersunk screw (40), the clip nut (45) and the angle (35) from the jamp assy (30). (e) Remove the countersunk screws (60) and the lower attachment bracket (55) from the jamp assy (30). (9) Housing 3 assy (-5) (a) Remove the kick strip (25) from the side wall (10).

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F. Removal of the Bi-Folding Door Assy (-1, Fig 7)(Refer IPL, Fig 8) (1) Slide down the knob (40; fig 8) on the lower part of the door, slide up the knob (40; fig 8) on the upper part of the door and turn the bolt (40; fig 8) around 90°. (2) Lift up the bi-folding door assy (-1, fig 8) and remove it finally. (3) Remove the countersunk screw (85) and the stop (80) from the bracket (65). (4) Remove the bushing (70) from the bracket (65). (5) Remove the countersunk screws (15) and the bracket (65) from the lavatory structure. (6) Remove the countersunk screws (15, 75) and the bracket (60) from the lavatory structure. (7) Remove the countersunk screws (55), the sill (45) and the spacer (50) from the floor pan. (8) Remove the countersunk screws (15), the profiles (5, 10, 25, 30) and the clip nuts (20) from the lavatory structure. (9) Remove the profile (35) from the lavatory structure. (10) Remove the countersunk screw (15), the clip nut (20) and the bracket (105). (11) Remove the bumper (40). (12) Remove the countersunk screws (115) and the micro switch (110) from the lavatory structure. (13) Remove the countersunk screws (95), the washers (100) and the block (90) from the lavatory structure. G. Disassembly of the Bi-Folding Door Assy (Refer IPL, Fig 8) (1) Remove the countersunk screws (105) and the profiles (80, 85). (2) Remove the countersunk screws (105, 250) and the profiles (90, 95, 245). (3) Removal of the spring installation assy (260) (a) Remove the setscrew (230) from the bolt (265).

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(b) Remove the bolt (265), the countersunk screws (145), the mounting part (255), the stop assy (290), the spring (275), the washers (270, 280) and the hexagonal nut (285) from the bi-folding door assy (-1). (c) Stop assy (290) 1 Remove the pin (295) from the stop (291). (4) Remove the knobs (40). (5) Remove the countersunk screws (60) and the locking plate (300). (6) Remove the countersunk screws (20) and the plate (305) from the bolt (5). (7) Remove the bolt (5) and the spring (310) from the upper part of the door plate. (8) Remove the countersunk screws (60) and the covers (50, 55). (9) Remove the bearing (65), the bolt (35) and the spring (45) from the upper part of the door plate. (10) Remove the countersunk screw (240), the washer (235), the bearing (215), the bolt (210) and the spring (45) from the lower part of the door plate. (11) Removal of the ashtray assy (160) (a) Remove the ashtray insert (-162) from the ashtray casing (-161). (b) Remove the countersunk screws (100) and the ashtray casing (-161). (12) Remove the countersunk screw (155) and the coat hook (150). (13) Door lock assy (315) (a) Remove the knob (330) from the lock (320). (b) Remove the screws (335, 340) and the escutcheon (325). (c) Remove the countersunk screws (60) and the lock (320) from the bi-folding door assy. (14) Remove the countersunk screws (140) and the grip (135) and the folding door handle (130). (15) Remove the pan-head screws (115) and the air grids (110) from the bi-folding door assy. (16) Remove the countersunk screws (75) and the stops (165) from the hinge (70). (17) Remove the bumpers (220) from the hinge (70).

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(18) Remove the countersunk screws (75), the profiles (10, 30) and the hinge (70) with the setscrews (71) from the door plate. (19) Remove the countersunk screws (15), the profile (25) and the hinge (70) with the setscrews (71) from the door plate. (20) Hinge (70) (a) Remove the setscrew (71) from the hinge (70). (21) Remove the countersunk screws (60) and the bushing (170). (22) Remove the countersunk screws (205) and the lock assy (175) from the upper part of the door plate. (23) Lock assy (175) (a) Remove the bolt (190) and the spring (200) from the bracket (185). (b) Remove the bracket (185) and the knob (195) from the plate (180). (24) Remove the push plates (225). (25) Remove the kick strips (120, 125) from the bi-folding door assy. H. Removal of the Toilet Unit and of the Toilet Shroud (Refer IPL, Fig 9) (1) Removal of the toilet seat assy (40) (a) Remove the unpainted nuts (90), the gaskets (85) and the toilet seat assy (40) from the toilet shroud assy (5). (b) Remove the unpainted fasteners (75, 80) and the unpainted toilet cover (65) from the unpainted toilet seat (50). 1 Remove the sealing (70) from the unpainted toilet cover (65). 2 Remove the sealing (55) from the unpainted toilet seat (50). (2) Remove the fasteners (115) and the toilet shroud assy (5) with the spacers (20) from the support assemblies (95, 105). (3) Toilet shroud assy (5) (a) Remove the countersunk screws (15) and the spacers (10) from the toilet shroud assy (5).

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(4) Remove the hexagonal screws (25), the washers (35) and the support assy (95) from the lavatory structure. (a) Remove the sealing profile (100) from the support assy (95). (5) Remove the hexagonal screws (30), the washers (35) and the support assy (105) from the lavatory structure. (a) Remove the sealing profile (110) from the support assy (105). (6) Remove the screws (-195), the hexagonal nuts (185), the bushings (160, 180) and the recurculating toilet module (135) from the tie rod assemblies (145, 165) and from the lavatory structure. NOTE: For further instructions refer to CMM TBD (toilet module). (7) Remove the quick release pins (190) and the tie rod assemblies (145, 165) from the brackets (120, 125). (8) Tie rod assemblies (145, 165) (a) Remove the rod ends (155, 175) from the tie rods (150, 170). (9) Remove the hexagonal screws (25), the washers (140) and the brackets (120) from the lavatory structure. (10) Remove the hexagonal screws (130), the washers (140) and the brackets (125) from the lavatory structure. J. Removal of the Floor Pan (refer IPL, fig 10) (1) Remove the hexagonal screws (125), the washers (130) and the floor pan assy (70) from the floor panel assy (10) and from the lavatory structure. (2) Remove the countersunk screws (90) and the floor panel assy (10) from the lavatory structure. (3) Floor panel assy (10) (a) Remove the hexagonal screws (30), the washers (35), the angle assemblies (15) and the clip nuts (40) from the angle (45). (b) Angle assy (15) 1 Remove the spring clip (25) from the angle (20). (c) Remove the hexagonal screws (50), the washers (35) and the angle (45) from the floor panel assy (10).

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(d) Remove the sealing (-55) from the floor panel assy (10). (4) Floor pan assy (70) (a) Remove the NTF-covering (80) with the adhesive tape (85) from the floor pan assy (70). (5) Sign mounting assy (95) (a) Remove the flush label (110) from the frame (100). (b) Remove the countersunk screws (115), the frame (100) and the plate (105) from the floor panel assy (10). K. Removal and Disassembly of the Washstand Unit (Refer IPL, Fig 11) (1) Remove the ground cable from the vanity assy (5). (2) Remove the hexagonal screws (65), the washers (70) and the lanyard (105) from the washstand door assy (125) and from the vanity assy (5). (3) Remove the countersunk screws (225) and the washstand door assy (125) from the vanity assy (5). (4) Remove the placards (230, 235) from the washstand door assy (125). (5) Washstand door assy (125) (a) Remove the countersunk screws (190) and the hinge (185) from the washstand door assy (125). (b) Remove the countersunk screws (205) and the latch (200) from the washstand door assy (125). (c) Remove the countersunk screws (180) and the waste flap assy (140) from the washstand door assy (125). (d) Waste flap assy (140) 1 Remove the foam sheet (175) from the frame (150). 2 Remove the countersunk screws (155), the washers (160), the hexagonal nuts (165) and the waste flap (145) with the springs (-170) from the frame (150). (e) Remove the sliding strips (195) from the washstand door assy (125).

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(f) Remove the pan-head screws (75), the countersunk screws (100), the clip nuts (95) and the washstand cover (110) from the vanity assy (5) and from the lavatory structure. (g) Paper roll holder (210) 1 Remove the roll holders (215) from the paper roll holder (210). 2 Remove the paper roll holder (210) from the washstand cover (110). (h) Remove the hexagonal screws (65), the washers (70) and the washbasin (240) from the vanity assy (5). (j) Remove the pan-head screws (80), the hexagonal screws (65), the washers (70) and the vanity assy (5) from the lavatory structure. (k) Remove the hexagonal screws (65), the washers (70) and the angles (30, 35, 40, 45, 50, 55) from the vanity assy (5). (l) Vanity assy (5) 1 Remove the section (10) from the vanity assy (5). (m) Remove the pan-head screws (85), the washers (90) and the strike (60) from the angle (40). L. Removal and Disassembly of the Waste Bin, the Waste Chute and the Fire Extinguisher (Refer IPL, Fig 12) (1) Remove the waste box (5). (2) Remove the hexagonal screws (80), the washers (85), the hexagonal nuts (90) and the fire extinguisher (75). NOTE: For further instructions refer to CMM 26-25-36 (fire extinguisher). (3) Remove the hexagonal screws (65), the washers (70) and the shelf assy (10) from the lavatory structure. (4) Shelf assy (10) (a) Remove the countersunk screws (20), the washers (25), the hexagonal nuts (30) and the cover (15) with the adhesive foil (35) from the shelf assy (10). (5) Remove the countersunk screws (120), the washers (85), the hexagonal nuts (125) and the door ejector assy (95) from the shelf assy (10). (6) Door ejector assy (95)

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(a) Remove the pin (110), the door ejector pin (105) and the spring (115) from the door ejector housing (100). (7) Remove the sliding strips (40, 45, 50) and the sealing profiles (55, 60) from the lavatory structure. M. Disassembly of the Ventilation System (Refer IPL, Fig 13) (1) Remove the cap (80) and the air outlet (75) from the ventilation assy (5). (2) Ventilation assy (5) (a) Remove the countersunk screws (35) and the air extraction grill (30) with the air grill (40) and the fleece (45) from the air extraction housing (15). (b) Remove the pan-head screws (60), the washers (65), the hexagonal nuts (70) and the plate (55) from the air extraction housing (15). (c) Remove the countersunk screws (20) and the air extraction housing (15) from the ventilation assy (5). (d) Remove the adapter (50) from the air extraction housing (15). N. Disassembly of the Water System (Refer IPL, Fig 14) (1) Remove the clamp (15) and the drain assembly (5) from the hose (10). NOTE: For further instructions refer to CMM 38-31-14 (drain assembly) (2) Remove the ground cable from the drain valve (20). (3) Remove the clamps (15) and the hose (10) from the drain valve (20). NOTE: For further instructions refer to CMM 38-30-30 (drain valve) (4) Remove the clamps (15) and the hose (55) from the drain valve (20) and the covering plate (60). (5) Remove the hexagonal screws (25), the washers (30), the hexagonal nuts (35) and the drain valve (20) from the drain valve bracket (40). (6) Remove the hexagonal screws (45), the washers (50) and the drain valve bracket (40) from the lavatory structure.

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(7) Remove the hexagonal screws (45), the washers (50) and the covering plate (60) from the lavatory structure. (8) Remove the countersunk screws (70) and the freighter drain flange (65) from the lavatory structure. (9) Remove the clamps (95) and the hose (85) from the bottom plate (90). (10) Remove the hexagonal screws (45), the washers (50) and the bottom plate (90) from the lavatory structure. (11) Remove the hexagonal screws (45), the washers (50) and the cable support (75) from the lavatory structure. (12) Remove the hexagonal screws (45), the washers (50) and the cover (80) from the lavatory structure. P. Disassembly of the Electrical System (Refer IPL, Fig 15) (1) Disconnect the cables and the bonding wires (160, 165, 170, 175, 180, 185) from the electrical components (2) Remove the cable loom (5). (3) Remove the chime (10). (4) Remove the hexagonal screw (25), the washers (30)), the clip nut (35), the angle (20) and the clamp (15). (5) Remove the angle (50), the relay socket (45) and the relay (40). (6) Remove the wash table light (55), the mirror light (60), the RTS-signs (65) and the timer assembly (230). NOTE: For further instructions refer to CMM 38-33-13 (timer assembly) (7) Bracket assemblies (70, 140) (a) Remove the hexagonal screws (-80, -150), the washers (-85, -155) and the cable brackets (-75, -145). (8) Bracket assy (90) (a) Remove the hexagonal screw (-100), the washers (-105), the hexagonal nut (-110) and the cable bracket (-95). (9) Bracket assy (115)

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(a) Remove the hexagonal screw (-125), the washer (-130), the spacer (-135) and the cable bracket (-120). (10) Bracket assy (190) (a) Remove the hexagonal screws (-210), the washers (-205, -215), the end clamps (-200), the modules (-195) and the rail (-220). (11) Remove the hexagonal screws (225) and the washers (30). (12) Remove the bracket (235). Q. Disassembly of the Cable Loom (Refer IPL, Fig 16) (1) Remove the backshell (10) and the receptacle (5) from the bracket (25). (2) Remove the countersunk screws (30), the hexagonal nut (35) and the bracket (25). (3) Remove the pins (75), the clamps (80), the plugs (65) and the backshells (70). (4) Remove the pins (75), the end clamps (90), the terminal boards (95) and the rail (85).

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PAGE 314 SEP 23/09 25-41-01



CLEANING WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE THE CLEANING AGENT (MATERIAL NO. 11-003). THIS CLEANING AGENT IS DANGEROUS. CAUTION: USE ONLY THE SPECIFIED CLEANING AGENTS. UNSPECIFIED CLEANING AGENTS CAN CAUSE DAMAGE. 1. GENERAL A. For the cleaning procedures of the subcomponents refer to the manufacturer's manuals written in chapter DESCRIPTION AND OPERATION. 2. Equipment and Materials

NOTE: Refer to the LIST OF MATERIALS for the material specification. --------------------------------------------------------------------------------- NAME DESIGNATION --------------------------------------------------------------------------------- A. Material No. 11-003 Cleaning Agent B. Material No. 11-010 Cleaning Agent C. Material No. 11-016 Cleaning Agent D. Material No. 14-001 Disinfectant

3. PROCEDURES A. Disinfect the countertop areas, undersink area and toilet shroud with disinfectant (Material No. 14-001). B. Remove all the loose dirt with a vacuum cleaner or a soft brush. C. Remove all the old sealant and the dirt with the cleaning agent (MATERIAL NO 11-003) or with a nonmetallic scraper. D. Cleaning of the PU-coatings, the PA-materials, the painted components, the PC- and the PVF-Films NOTE: Do not wash PC-films with MEK or trichloroethylen. (1) Clean the PU-coatings, the PA-materials, the painted components, the PV- and the PVF-films with a mild soap solution. Use a soft brush or a clean, lintfree cloth. (2) Dry all the parts with a clean, dry, lintfree cloth of a hot-air blower.

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E. Cleaning of the Stainless Steel Parts (1) Clean all the stainless steel parts with the polishing cleaner (Material No. 11-016). F. Electrical System CAUTION: REMOVE THE ELECTRICAL POWER IF YOU WORK ON THE EQUIPMENV WITH ELECTRICAL INSTALLATION. (1) Lightly clean all the electrical parts which you can get access to with a soft nonmetallic brush. (2) Blow the loose dust and the dirt from all parts with dry, filtered air. (3) Clean the surfaces of the electrical units with a clean, lintfree cloth or a soft bristle brush moist with isopropyl alcohol (MATERIAL NO. 11-010) and permit to air dry. G. Water System (1) Flush the full installation system with the solution of disinfectant (Material No. 14-001) or an equivalent, and distilled water. (2) Flush the full installation system with fresh potable water. (3) Use clean, dry compressed air to blow out and dry parts.

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C H E C K

1. GENERAL A. For repair procedures refer to chapter REPAIR. B. For the check procedure of the subcomponents refer to the manufacturer’s manuals written in DESCRIPTION AND OPERATION. 2. Equipment and Materials None 3. Procedure A. Attachment of Subcomponents (1) Examine all the attachment points for correct condition. (a) Tighten the attachments if necessary. B. Sandwich Panels and Doors (1) Examine the sandwich panels and the doors for deformation, cracks, holes and delamination. (a) Replace the deformed sandwich panels and doors. (b) The maximum edge length of damaged areas is 200 mm x 200 mm (7.9 inch x 7.9 inch). (c) Rebond the delaminated decorative material. C. Threaded Inserts (1) Examine the threaded inserts for correct installation and condition of the thread. (a) Replaced damaged inserts.

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D. Metal Parts (1) Examine the metal parts for damage and correction. E. Upper And Lower Attachment fittings (1) Examine the upper and the lower attachment fittings for cracks, loose fit and dam aged holes. (a) If any upper or lower attachment fitting shows any signs of damage you must replace it. F. Sealing Strips (1) Examine the sealing strips for wear, correct fit and alignment. G. Air Vent (1) Examine the attachment and the condition of the air vent. (2) Make sure that the opening of the air vent is clean. H. Latches and Fasteners (1) Examine the correct operation of the latches and the fasteners. (2) Make sure that the latches and the fasteners are clean. J. Placards (1) Examine the placards for presence and attachment. K. Water System (1) Examine the clamps and the supports for attachment and damage. (2) Examine the hoses, the tubes, the fittings and the hose connections for attachment, damage and leaks. (3) Examine the hoses and the gaskets and/or O-rings for signs of ageing. (a) Replaced damaged hoses, gaskets and/or O-rings.

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L. Electrical System (1) Examine all the electrical connections for tightness and contact. (2) Make sure that the connections are clean. (3) Examine the plugs and receptacles and make sure that there are no pins loose, broken or missing. (4) Examine the terminal lugs for firm connection on wire ends. (5) Examine the connections on the terminal boards and the ground studs for corrosion. (6) Examine the soldered and the crimped connections for attachment. (7) Examine the lavatory light lens for damage and presence. (8) Make sure that the lavatory light lens is clean.

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PAGE 504 SEP 23/09 25-41-01



REPAIR

WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE THE SOLVENTS, CLEANING AGENTS OR

SEALANTS USE PROTECTIVE CLOTHING, RUBBER GLOVES, GOGGLES AND A MASK. WARNING: MAKE SURE THAT THERE IS A GOOD FLOW OF AIR THROUGH THE WORK AREA WHEN YOU USE THE

SPECIAL MATERIALS. IF YOU GET ONE OF THESE MATERIALS ON YOUR SKIN, IN YOUR MOUTH OR IN YOUR EYES: FLUSH IT AWAY WITH A FLOW OF CLEAN WATER FOR BETWEEN 10 TO 15 MINUTES. GET IMMEDIATE MEDICAL AID IF IRRITATION OCCURS. DO NOT BREATH THE FUMES FROM THE MATERIAL. DO NOT SMOKE WHEN YOU USE THE MATERIAL. DO NOT USE THE MATERIAL NEAR A FLAME, SPARKS OR SOURCES OF HEAT. THESE MATERIALS ARE DANGEROUS: THEY ARE POISONOUS, FLAMMABLE AND SKIN IRRITANTY. CAUTION: USE ONLY THE SPECIFIED MATERIALS. MATERIALS WHICH ARE NOT SPECIFIED CAN CAUSE

DAMAGE. 1. General A. For the repair procedure of the subcomponents refer to the supplier's manuals. (refer to chapter DESCRIPTION AND OPERATION) B. Do not use KETONE or ACETONE for the cleaning of these parts after the repair: - the floor pan, - the toilet shrouds with the supports, - the air grids, - all the parts made of poly carbonate. Cover these parts if you work with KETONE or ACETONE to prevent of moist. Use only ETHANOL (Material No. 11-520) to clean the parts made of poly-carbonate. C. Replace these parts during the disassembly procedure: - the screws of lower and upper attachments and all selflocking nuts, - all the seals, - all the bulbs and the fluorescent tubes. D. For the rivet replacement refer to the standard riveting procedure.

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2. Equipment and Materials NOTE: Refer to the LIST OF MATERIALS for the specification of the consumable materials. ----------------------------------------------------------------------------- NAME DESIGNATION ----------------------------------------------------------------------------- A. Material No. 04-012 Common Grease B. Material No. 05-033 Glasscloth C. Material No. 05-035 Special Material D. Material No. 05-056 Glasscloth E. Material No. 05-057 Special Material F. Material No. 05-109 Laminate G. Material No. 05-531 Solder H. Material No. 07-012 Paint J. Material No. 08-001C Adhesive K. Material No. 08-017A Adhesive L. Material No. 08-025 Adhesive M. Material No. 08-025B Adhesive N. Material No. 08-026 Adhesive P. Material No. 08-036 Polyester Filler Q. Material No. 08-082 Adhesive Film R. Material No. 08-529 Adhesive S. Material No. 08-553 Adhesive T. Material No. 08-618 Adhesive U. Material No. 08-707 Adhesive V. Material No. 09-521 Sealant W. Material No. 11-003 Cleaning Agent X. Material No. 11-010 Cleaning Agent Y. Material No. 11-520 Cleaning Agent Z. Material No. 11-583 Cleaning Agent AA. Material No. 13-003 Coating AB. Material No. 16-003 Coating AC. Material No. 16-046 Primer AD. Material No. 16-047 Paint AE. Abrasive paper 180-400 grade of grain Abrasive Paper No specific Applicable Cleaning Agent For Steanless Steel No specific Drill No specific Lint-Free Cloth No specific Milling Cutter No specific Rubber Base Plate No specific Separating Foil

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3. List of the Procedure A. Repair of the Structure Sandwich Panels B. Repair of the Floor Pan C. Repair of the Decorative Foils D. Repair of the Scratches and of the other Damages on the Anodized Surfaces E. Repair of the Damaged Paint F. Repair of the Defective Sealing Profiles G. Repair of the Electrical System H. Removal of the Corrosion J. Repair of the Inserts of the Sandwich Panels K. Repair of the Polycarbonate L. Repair of the Mirror M. Repair of the Toilet Shroud Assembly 4. Procedure A. Repair of the Structure Sandwich Panels (1) For damage deeper than 1 mm (0.093 in) and less than 50 mm (1.9685 in) diameter.

(refer to figure 601) (a) Cut out the damaged skin. (b) Cut out the damaged core up to a maximum of 50 mm (1.9685 in) diameter. (c) Make the repair rough with the abrasive paper, 320-400 grade of grain. (d) Make an external doubler of the SPECIAL MATERIALS (Material No. 05-033) to

overlap the damage by 50 mm (1.9685 in). (e) Clean the area of the repair with the CLEANING AGENTS (Material No. 11-010) and

a lint free cloth. (f) Fill the repair. 1 Prepare a mixture of 85 parts BONDING and ADHESIVE COMPOUNDS (Material No.

08-001C) and 15 parts SPECIAL MATERIALS (Material No. 05-057) by volume. 2 Fill the repair with the compound. 3 Cut a plug of the SPECIAL MATERIALS (Material No. 05-035) to fit the re-

pair. 4 Apply the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-001C) to the

repair area and the plug (2). 5 Put the plug (2) in the repair.

PAGE 603 SEP 23/09 25-41-01



(g) Apply the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025) to the repair. (h) Apply the external doubler (1) to the repair. (j) Apply the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025) to the ex-

ternal doubler (1).

Figure 601

PAGE 604 SEP 23/09 25-41-01



(2) For damage larger than 50 mm (1.969 in) diameter (refer to figure 602). (a) Cut out the damaged skin. (b) Cut out the damaged core. (c) Make an external doubler of the SPECIAL MATERIALS (Material No. 05-033) to

overlap the damage by 50 mm (1.969 in). (d) Make a plug of honeycomb core to fit the repair. (e) Clean the area of the repair with the CLEANING AGENTS (Material No. 11-010) and

a lint-free cloth. (f) Apply the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-001C) to the re-

pair and the honeycomb core. (g) Fill the gap around the plug (2) with the BONDING and the ADHESIVE COMPOUNDS

(Material No. 08-001C) (3). (h) Apply the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025) to the area

of the repair. (j) Apply the external doubler (1) to the repair. (k) Apply the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025) to the doub-

ler.

PAGE 605 SEP 23/09 25-41-01



Figure 602

PAGE 606 SEP 23/09 25-41-01



B. Repair of the Floor Pan (1) Removal and installation of the NTF-covering (a) Removal of the NTF-covering 1 Remove the NTF-covering from the floor pan. 2 Remove the remaining adhesive and the sealant. (b) Installation of the NTF-covering 1 Install the NTF-covering to the floor pan with the ADHESIVE FILM (Material

No. 08-082). 2 Seal the edges of the NTF-covering with the ADHESIVE (Material No. 08-026). (2) Cracks or damages in the floorbottom (around the NTF-covering, underneath the NTF-

covering, behind the toilet shroud and underneath the washbasin) (refer to figure 603)

(a) Drill a hole of 3.5 mm (0.13 in) at each end of the crack to "secure" it. (b) Remove the damage with a milling cutter and / or a drill (refer to figure 603). (c) Clean the repair and smooth the area of stiffener with the abrasive paper, 320-400 grade of grain. (d) Fill the damaged area with the BONDING and the ADHESIVE COMPOUNDS (Material No.

08-025). (e) Let the BONDING and the ADHESIVE COMPOUNDS cure for 1 hour. (f) Install a laminat made from GLASSCLOTH (Material No. 05-056) and ADHESIVE and HARDENER (Material No. 08-001C) on both sides. (g) If necessary, smooth the repair with abrasive paper, 320-400 grade of grain and apply LACQUER (Material No. 07-012).

PAGE 607 SEP 23/09 25-41-01



Figure 603

Figure 604

PAGE 608 SEP 23/09 25-41-01



(3) Cracks or damages in the vertical panel of the floor pan (refer to figure 604) (a) Drill a hole of 3,5 mm (0,138 in) at each end of the crack to "secure" it. (b) Remove the damage with a milling cutter and / or a drill (refer to figure 604). (c) Clean the repair area with the CLEANING AGENT (Material No. 11-520). (d) Fill the damaged area with the BONDING and the ADHESIVE COMPOUNDS (Material No.

08-025). (e) Make a stiffener from a LAMINAT (Material No. 05-109) (refer to figure 604). (f) Bond the stiffener to the repair area with the BONDING and the ADHESIVE

COMPOUNDS (Material No. 08-025). (g) If necessary, smooth the repair with abrasive paper, 320-400 grade of grain and

apply LACQUER (Material No. 07-012). NOTE: Repair the damage that is 10 mm (0,394 in) or larger in diameter. (4) Preventive pad solution (refer to figure 605) (a) Make pads 50 mm x 50 mm (1.969 in x 1.969 in) from laminate (Material No. 05-

109) or polycarbonat plates DAN 197/198 or similiar. (b) Bond the pads to the floor pan with the ADHESIVE (Material No. 08-017A). (c) Paint with the lacquer (Material No. 07-012). (5) Sealant around the NTF-covering (a) Check the sealant around the NTF-covering. If necessary repair or fill the

damage area with the ADHESIVE (Material No. 08-026). (6) Scratches on the surface NOTE: Use only ETHANOL (Material No. 11-520) to clean the floor pan. (a) Remove the loose dirt and the dust. (b) Close the scratches with the Polyester FILLER (Material No. 08-036). (c) Paint the repaired area.

PAGE 609 SEP 23/09 25-41-01



(7) Broken floor pan NOTE: Remove the broken floor pan. The repair is not possible, if:

- the crack is longer than 710 mm (27.953 in) - 2 cracks at less than 51 mm (2 in) from each other - the cracks occur like shown in figure 605

Figure 605

PAGE 610 SEP 23/09 25-41-01



(a) Removal of the floor pan screwed 1 Replace the broken floor pan. (8) The replacement of the damaged floor pan inserts (for toilet unit fixation) (a) Remove the damaged floor pan insert. (b) Enlarge the hole to 17.4 mm (0.685 in) diameter (refer to figure 606). (c) Bond the repair insert with the ADHESIVE (Material No. 08-017A). NOTE: Use the repair insert NAS 1833C4-370 as per drawing. (9) Repair of the floor pan surrounding inserts (a) Remove the damaged floor pan inserts and the damaged area. (b) Clean the repair area with the CLEANING AGENTS (Material No. 11-520). (c) Fill the damaged area with the BONDING and the ADHESIVE COMPOUNDS (Material No.

08-017A) (refer to figure 607). (d) Make a stiffener from a LAMINAT (Material No. 05-109) or similar as shown be-

low. (refer to figure 608) (e) Bond the stiffener to the repair area with the ADHESIVE (Material No. 08-017A)

(refer to figure 608). (f) Bond the repair insert NAS 1833C4-370 with the ADHESIVE (Material No. 08-017A).

PAGE 611 SEP 23/09 25-41-01



Figure 606

Figure 607

PAGE 612 SEP 23/09 25-41-01



Figure 608

PAGE 613 SEP 23/09 25-41-01



C. Repair of the Decorative Foils (1) The decorative foil is partly delaminated from the structure. (a) Bond the delaminated foil with the ADHESIVE (Material No. 08-553). (b) Apply pressure to the decorative material until the adhesive has cured. (c) Remove any unwanted adhesive with a cloth moist with the CLEANING AGENT ACETONE (Material No. 11-583). (2) The decorative foil has delaminated in large areas from the structure. (a) Remove all of the decorative foil from the surface. NOTE: Use heat or solvents like MEK (Material No. 11-003) or ACETONE (Material No. 11-583) to help removal. CAUTION: MAXIMUM TEMPERATURE IS 80° C (176° F). CAUTION: HEAT ONLY SMALL AREAS OF THE SURFACE. DO NOT DAMAGE THE PANEL SKIN. (b) Remove the remaining adhesive from the bonding surface with the CLEANING AGENT

ACETONE (Material No. 11-583). (c) Bond the decorative foil with the ADHESIVE (Material No. 08-553). (d) Apply pressure to the decorative foil until the adhesive has cured. (3) Hole or crack in decorative foil (a) Minor damage, for example scratches or cracks may be temporarily repaired with

paint or with a patch. These repairs are always visible. It may be necessary to remove the decorative foil of the whole surface during the overhaul of the lavatory.

1 Fasten a patch of the same decorative foil over the damaged area with adhe-

sive tape. 2 Cut out a applicable sized area of the patch so as to make a mark on the

decorative foil of the lavatory. 3 Remove the marked area of decorative foil of the lavatory and the remaining

adhesive. 4 Bond the patch with the ADHESIVE (Material No. 08-553). 5 Apply pressure to the decorative foil until the adhesive has cured.

PAGE 614 SEP 23/09 25-41-01



D. Repair of the Scratches and of the other Damages on the Anodized Surfaces (1) Polish the scratches and the adjacent anodized surface with the abrasive paper 200

grade of grain or finer. (2) Remove any grease and clean the surface with a dry, clean, lintfree cloth. (3) Apply the COATING (Material No. 13-003) to the prepared surface. E. Repair of the Damaged Paint (1) Mask area around the scratch. (2) Polish the scratch smooth with 240 grade of grain abrasive paper. (3) Remove any grease and clean the damaged surface with a dry, clean lint-free cloth. (4) Apply filler. Use LACQUER (Material No. 07-012) for all parts on the inside of the

lavatory and PRIMER (Material No. 16-046) for all parts on the outside of the lava-tory.

NOTE: Do not apply the filler to PC-parts. (5) Remove the masking tape and polish the filler edges with 320 grade of grain abrasive paper. (6) Clean the repaired area. (7) Apply lacquer. Use LACQUER (Material No. 07-012) for all parts on the inside of the

lavatory and PAINT (Material No. 16-047) for all parts on the outside of the lava-tory.

(8) Paint the whole component in case of large damage. F. Repair of the Defective Sealing Profiles (1) Remove the defective sealing profiles. (2) Clean the bonding area with the CLEANING AGENT (Material No. 11-010) and bond the

new sealing profile with the ADHESIVE (Material No. 08-026).

PAGE 615 SEP 23/09 25-41-01



G. Repair of the Electrical System (1) Defective wiring (a) Replace defective wiring you find during inspection. (b) You may splice defective or cracked wires to repair them. (2) Soldered wire terminations (a) Unsolder old wiring and solder new wires, refer Military Specification MIL-S-6872, use SOLDER (Material No. 05-531). (3) Electrical components (a) Replace all electrical components which do not pass inspection requirements or

are found to be defective during inspection. (b) Coat ground studs with the COATING (Material No. 16-003) after installation. NOTE: Clean the grounding area before installation of ground studs in order to get a low transfer resistance. H. Removal of the Corrosion NOTE: The max. permitted depth of corrosion is 0.25 mm (0.010 in). CAUTION: THE MAX. ALLOWED AMOUNT OF MATERIAL REMOVED FROM ANY DAMAGED SURFACE IS GIVEN

FROM THE CONSTRUCTIVE REQUIREMENTS OF THE COMPONENTS. ATTACHING ELEMENTS AND STATICALLY LOADED PARTS HAVE TO BE REPLACED.

(1) Remove the corrosion and make a shallow groove to prevent stress concentration. (2) Clean the reworked area with the CLEANING AGENT (Material No. 11-010). (3) Apply protective treatment (Material No. 13-003). J. Repair of the Inserts of the Sandwich Panels (1) Removal of the damaged inserts (a) Remove the damaged inserts. (b) Clean the repair area with the CLEANING AGENT (Material No. 11-003).

PAGE 616 SEP 23/09 25-41-01



(2) Installation of the new inserts NOTE: Use the same type and size of insert removed. (a) Fill the damaged area with the BONDING and the ADHESIVE COMPOUNDS (Material No.

08-017A). (b) Drill the required hole for the insert into the panel. (c) Remove the covering paper from the tab. Bond the tab onto the insert. (d) Press the insert on the tab. (e) Install the insert into the hole of the panel. (f) Bond the insert to the panel with the ADHESIVE (Material No.08-017A). Use the potting holes of the insert. (g) Remove the tab after the curing of the adhesive (approximately 24 hours).

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Figure 609

PAGE 618 SEP 23/09 25-41-01



K. Repair to Polycarbonate Sheet Component (refer to figure 609) (1) If the component is cracked, you must stop drill the ends of the crack. (2) Remove the damage that has gone through the component with a milling cutter and /

or a drill. (3) Clean the repair with the CLEANING AGENTS (Material No. 11-010) and a lint-free

cloth. (4) Repair the damage that is less than 10 mm (0.397 inch) in diameter. NOTE: Only do this repair when the distance from the damaged area to a support or attachment point is more than 40 times the component thickness. (a) Apply the separating foil (1) to the front face of the component (3). (b) Put the component (3), front face down on a rubber base plate (2). (c) Fill the damaged area with the BONDING and the ADHESIVE COMPOUNDS (Material No.

08-025) (4). (d) Let the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025) cure for 1 hour. (e) Remove the separating foil (1) from the component (3). (f) Fill the areas that are not smooth with the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025). (g) If necessary, smooth the repair with the abrasive paper, 320-400 grade of

grain.

(5) Repair the damage that is 10 mm (0.397 inch) or larger in diameter.

(a) Make an insert from the applicable PC-material.

(b) Chamfer the edges of the component (5) to 45 degrees. (c) Chamfer the edges of the insert (7) to 45 degrees.

(d) Apply the separating foil (1) to the front face of the component (5).

(e) Put the component (5), front face down, on a rubber base plate (2).

(f) Smooth the repair with the abrasive paper, 320-400 grade of grain.

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(g) Clean the repair area with the CLEANING AGENTS (Material No. 11-010) and a

lint-free cloth.

(h) Bond the insert (7) to the component (5) with the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025).

(j) Make a stiffener from the SPECIAL MATERIALS (Material No. 05-033) (6). (k) Apply the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025) to the re-

pair area. (l) Apply the SPECIAL MATERIALS (Material No. 05-033) (6) to the repair area. NOTE: The thickness of the SPECIAL MATERIALS (Material No. 05-033) (6) must equal

0-5 times the component thickness. The minimum distance from the edge of the stiffener to the insert must equal 20 times the component thickness.

NOTE: With flat components a polycarbonate sheet equal to the component thickness is bonded to the component as an alternative to the SPECIAL MATERIALS (Material No. 05-033). (m) Remove the separating foil (1) from the component (5). (n) Fill the areas that are not flat with the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025). (p) If necessary, smooth the area of the repair with the abrasive paper 320-400

grade of grain. (q) If necessary apply a top layer. L. Repair of the Mirror NOTE: The manufacturer repairs the mirror by exchange. (1) Removal of the mirror (a) Remove the screws, the washers and the mirror from the lavatory wall. (2) Send the defect mirror to the manufacturer (Fa. DASELL C5270). You get a new one by exchange. (3) Installation of the mirror (a) Install the mirror to the lavatory wall with the screws and the washers.

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M. Repair of the toilet shroud assembly (1) Separation of the ring cover from the toilet shroud (a) Remove the cracked ring cover from the toilet shroud. NOTE: Heat up the joint to maximum temperature of 80° C (176°F) if required. (b) Use the abrasive paper, 320-400 grade of grain, to remove the remaining adhe-

sive. (c) Clean the bonding area with the CLEANING AGENT ETHANOL (Material No. 11-520). (2) Bonding of the ring cover to the toilet shroud (a) Bond the ring cover to the toilet shroud with the ADHESIVE (Material No. 08-017A). NOTE: Make sure that the both surfaces are placed correct, before you apply the adhesive. (b) Fill the visible areas with the Polyester FILLER (Material No. 08-036). (c) Smooth the bonding area with the abrasive paper, 320-400 grade of grain. (d) Repaint the complete unit. (3) Cracks or damages in the toilet shroud assembly (refer to fig 612) (a) Stop drill the ends of the crack. (b) Remove the damage with a milling cutter and / or a drill. (c) Clean the repair and smooth the area of stiffener with the abrasive paper, 320-400 grade of grain. (d) Fill the damaged area with the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025B). (e) Let the BONDING and the ADHESIVE COMPOUNDS cure for 1 hour. (f) Install 2 laminates made from GLASS FABRIC LN9169-8-4548-6 with LAMINATION RESIN and HARDENER (Material No. 08-001C) on both sides of the shroud (refer to figure 611). (g) If necessary, smooth the repair with abrasive paper, 320-400 grade of grain and apply a color layer of the decorative paint (Material No. 16-047).

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(4) Cracks or damages in the area of the fixing holes of the toilet cover (refer to figure 610) (a) Stop drill the ends of the crack. (b) Remove the damage with a milling cutter and / or a drill. (c) Clean the repair. (d) Fill the damaged area with the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025B). (e) Let the BONDING and the ADHESIVE COMPOUNDS cure for 1 hour. (f) Make a stiffener from a laminated cloth plate LN40606B020 or similar (refer to figure 612). (g) Bond the stiffener to the repair area from the rear / back side with the BONDING and the ADHESIVE COMPOUNDS (Material No. 08-025B). (h) If necessary, smooth the repair with abrasive paper, 320-400 grade of grain and apply a color layer of the decorative paint (Material No. 16-047). (j) Drill new holes diameter 10 mm (0.394 inch) for the installation of the toilet cover.

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Mantra: 371-25-41

FIGURE 610

PAGE 623 SEP 23/09 25-41-01

-C4736, Rev: -, PRE-RELEASED


FIGURE 611

FIGURE 612

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A S S E M B L Y WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE THE CLEANING AGENT (MATERIAL NO. 11-003). THIS CLEANING AGENT IS DANGEROUS. CAUTION: USE ONLY THE SPECIFIED CLEANING AGENTS. UNSPECIFIED CLEANING AGENTS CAN CAUSE DAMAGE. WARNING: KEEP ALL HYDROCARBONS (FUELS, LUBRICANTS, ETC.) AWAY FROM ALL SOURCES OF OXYGEN. OXYGEN BECOMES EXPLOSIVE WHEN IT TOUCHES HYDROCARBONS. CLEAN THE TOOLS AND MAKE SURE YOUR HANDS ARE CLEAN TO PREVENT CONTAMINATION OF THE OXYGEN SYSTEM. CAUTION: PUT DRY, CLEAN, METAL OR PLASTIC PLUGS ON ALL PIPES OR UNITS REMOVED TEMPORARILY. PUT EACH PIPE OR UNIT IN A SEALED VINYL BAG. UNWANTED MATERIALS IN THE OXYGEN SYSTEM COULD DAMAGE THE SYSTEM. 1. GENERAL A. For the assembly procedures of the subcomponents refer to the manufacturer's manuals written in chapter DESCRIPTION AND OPERATION. B. Refer to the chapter REPAIR for the assembly of the component parts which have a permanent connection. C. If the paragraph refers to one figure, only the item number is given in the brackets. If the paragraph refers to more than one figure, the figure number and the item number are given in the brackets. D. Replace these parts during the assembly procedure: - the screws of the lower attachments and all selflocking nuts, - all the seals. - all the bulbs and the fluorescent tubes.

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2. EQUIPMENT AND MATERIALS NOTE: For the supplier's name and address refer to the chapter INTRODUCTION.

--------------------------------------------------------------------------------- NAME DESIGNATION --------------------------------------------------------------------------------- A. Material No. 04-012 Common Grease B. Material No. 08-048 Adhesive C. Material No. 11-003 Cleaning Agent D. Material No. 16-003 Coating

2. LIST OF PROCEDURE A. Assembly of the Cable Loom B. Assembly of the Electrical System C. Assembly of the Water System D. Assembly of the Ventilation System E. Installation and Assembly of the Waste Bin, the Waste Chute and the Fire Extinguisher F. Installation and Assembly of the Washstand Unit G. Installation of the Floor Pan H. Installation of the Toilet Unit and of the Toilet Shroud J. Assembly of the Bi-Folding Door Assy K. Installation of the Bi-Folding Door Assy L. Installation of the Lavatory Housing 3 M. Installation of the Lavatory Housing 2 N. Installation of the Rear Wall P. Installation and Assembly of the Pelmet Q. Installation of the Lavatory Attachment

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3. LAVATORY- ASSEMBLY NOTE: For the illustrations and the item numbers refer the chapter ILLUSTRATED PARTS LIST. A. Assembly of the Cable Loom (Refer IPL, Fig 16) (1) Install the rail (85), the terminal boards (95), the end clamps (90) and the pins (75). (2) Install the backshells (70), the plugs (65), the clamps (80) and the pins (75). (3) Install the bracket (25) with the countersunk screws (30) and the hexagonal nut (35). (4) Install the receptacle (5) and the backshell (10) to the bracket (25). B. Assembly of the Electrical System (Refer IPL, Fig 15) (1) Install the bracket (235). (2) Install the hexagonal screws (225) and the washers (30). (3) Bracket assy (190) (a) Install the rail (-220), the modules (-195) and the end clamps (-200) with the hexagonal screws (-210) and the washers (-205, -215). (4) Bracket assy (115) (a) Install the cable bracket (-120) and the spacer (-135) with the hexagonal screw (-125) and the washer (-130). (5) Bracket assy (90) (a) Install the cable bracket (-95) with the hexagonal screw (-100), the washers (-105) and the hexagonal nut (-110). (6) Bracket assemblies (70, 140) (a) Install the cable brackets (-75, -145) with the hexagonal screws (-80, -150) and the washers (-85, -155).

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(7) Install the wash table light (55), the mirror light (60), the RTS-signs (65) and the timer assembly (230). NOTE: For further instructions refer to CMM 38-33-13 (timer assembly) (8) Install the angle (50), the relay socket (45) and the relay (40). (9) Install the angle (20) and the clamp (15) with the hexagonal screw (25), the washers (30) and the clip nut (35). (10) Install the chime (10). (11) Install the cable loom (5). (12) Connect the cables and the bonding wires (160, 165, 170, 175, 180, 185) to the electrical components. C. Assembly of the Water System (Refer IPL, Fig 14) (1) Install the cover (80) to the lavatory structure with the hexagonal screws (45) and the washers (50). (2) Install the cable support (75) to the lavatory structure with the hexagonal screws (45) and the washers (50). (3) Install the bottom plate (90) to the lavatory structure with the hexagonal screws (45) and the washers (50). (4) Install the hose (85) to the bottom plate (90) with the clamps (95). (5) Install the freighter drain flange (65) to the lavatory structure with the countersunk screws (70). (6) Install the covering plate (60) to the lavatory structure with the hexagonal screws (45) and the washers (50). (7) Install the drain valve bracket (40) to the lavatory structure with the hexagonal screws (45) and the washers (50). (8) Install the drain valve (20) to the drain valve bracket (40) with the hexagonal screws (25), the washers (30) and the hexagonal nuts (35). (9) Install the hose (55) to the drain valve (20) and the covering plate (60) with the clamps (15). (10) Install the hose (10) to the drain valve (20) with the clamps (15). NOTE: For further instructions refer to CMM 38-30-30 (drain valve)

PAGE 704 SEP 23/09 25-41-01



(11) Install the ground cable to the drain valve (20). (12) Install the drain assembly (5) to the hose (10) with the clamp (15). NOTE: For further instructions refer to CMM 38-31-14 (drain assembly) D. Assembly of the Ventilation System (Refer IPL, Fig 13) (1) Ventilation assy (5) (a) Install the adapter (50) to the air extraction housing (15). (b) Install the air extraction housing (15) to the ventilation assy (5) with the countersunk screws (20). (c) Install the plate (55) to the air extraction housing (15) with the pan-head screws (60), the washers (65) and the hexagonal nuts (70). (d) Install the air extraction grill (30) with the air grill (40) and the fleece (45) to the air extraction housing (15) with the countersunk screws (35). (2) Install the air outlet (75) and the cap (80) to the ventilation assy (5). E. Installation and Assembly of the Waste Bin, the Waste Chute and the Fire Extinguisher (Refer IPL, Fig 12) (1) Install the sliding strips (40, 45, 50) and the sealing profiles (55, 60) to the lavatory structure. (2) Door ejector assy (95) (a) Install the door ejector pin (105), the spring (115) and the pin (110) to the door ejector housing (100). (3) Install the door ejector assy (95) to the shelf assy (10) with the countersunk screws (120), the washers (85) and the hexagonal nuts (125). (4) Shelf assy (10) (a) Install the cover (15) with the adhesive foil (35) to the shelf assy (10) with the countersunk screws (20), the washers (25) and the hexagonal nuts (30). (5) Install the shelf assy (10) to the lavatory structure with the hexagonal screws (65) and the washers (70).

PAGE 705 SEP 23/09 25-41-01



(6) Install the fire extinguisher (75) with the hexagonal screws (80), the washers (85) and the hexagonal nuts (90). NOTE: For further instructions refer to CMM 26-25-36 (fire extinguisher). (7) Install the waste box (5). F. Installation and Assembly of the Washstand Unit (Refer IPL, Fig 11) (1) Washstand door assy (125) (a) Install the strike (60) to the angle (40) with the pan-head screws (85) and the washers (90). (b) Vanity assy (5) 1 Install the section (10) to the vanity assy (5). (c) Install the angles (30, 35, 40, 45, 50, 55) to the vanity assy (5) with the hexagonal screws (65) and the washers (70). (d) Install the vanity assy (5) to the lavatory structure with the pan-head screws (80), the hexagonal screws (65) and the washers (70). (e) Install the washbasin (240) to the vanity assy (5) with the hexagonal screws (65) and the washers (70). (f) Paper roll holder (210) 1 Install the paper roll holder (210) to the washstand cover (110). 2 Install the roll holders (215) to the paper roll holder (210). (g) Install the washstand cover (110) to the vanity assy (5) and to the lavatory structure with the pan-head screws (75), the countersunk screws (100) and the clip nuts (95). (h) Install the sliding strips (195) to the washstand door assy (125). (j) Waste flap assy (140) 1 Install the waste flap (145) with the springs (-170) to the frame (150) with the countersunk screws (155), the washers (160) and the hexagonal nuts (165). 2 Install the foam sheet (175) to the frame (150).

PAGE 706 SEP 23/09 25-41-01



(k) Install the waste flap assy (140) to the washstand door assy (125) with the countersunk screws (180). (l) Install the latch (200) to the washstand door assy (125) with the countersunk screws (205). (m) Install the hinge (185) to the washstand door assy (125) with the countersunk screws (190). (2) Install the placards (230, 235) to the washstand door assy (125). (3) Install the washstand door assy (125) to the vanity assy (5) with the countersunk screws (225). (4) Install the lanyard (105) to the washstand door assy (125) and to the vanity assy (5) with the hexagonal screws (65) and the washers (70). (5) Install the ground cable to the vanity assy (5). G. Installation of the Floor Pan (refer IPL, fig 10) (1) Sign mounting assy (95) (a) Install the plate (105) and the frame (100) to the floor panel assy (10) with the countersunk screws (115). (b) Install the flush label (110) to the frame (100). (2) Floor pan assy (70) (a) Install the NTF-covering (80) with the adhesive tape (85) to the floor pan assy (70). (3) Floor panel assy (10) (a) Install the sealing (-55) to the floor panel assy (10). (b) Install the angle (45) to the floor panel assy (10) with the hexagonal screws (50) and the washers (35). (c) Angle assy (15) 1 Install the spring clip (25) to the angle (20). (d) Install the clip nuts (40) and the angle assemblies (15) to the angle (45) with the hexagonal screws (30) and the washers (35).

PAGE 707 SEP 23/09 25-41-01



(4) Install the floor panel assy (10) to the lavatory structure with the countersunk screws (90). (5) Install the floor pan assy (70) to the floor panel assy (10) and to the lavatory structure with the hexagonal screws (125) and the washers (130). H. Installation of the Toilet Unit and of the Toilet Shroud (Refer IPL, Fig 9) (1) Install the brackets (125) to the lavatory structure with the hexagonal screws (130) and the washers (140). (2) Install the brackets (120) to the lavatory structure with the hexagonal screws (25) and the washers (140). (3) Tie rod assemblies (145, 165) (a) Install the rod ends (155, 175) to the tie rods (150, 170). (4) Install the tie rod assemblies (145, 165) to the brackets (120, 125) with the quick release pin (190). (5) Install the recurculating toilet module (135) to the tie rod assemblies (145, 165) and to the lavatory structure with the screws (-195), the bushings (160, 180) and the hexagonal nuts (185). NOTE: For further instructions refer to CMM TBD (toilet module). (6) Install the support assy (105) to the lavatory structure with the hexagonal screws

(30) and the washers (35). (a) Install the sealing profile (110) to the support assy (105). (7) Install the support assy (95) to the lavatory structure with the hexagonal screws

(25) and the washers (35). (a) Install the sealing profile (100) to the support assy (95). (8) Toilet shroud assy (5) (a) Install the spacers (10) to the toilet shroud assy (5) with the countersunk screws (15). (9) Install the toilet shroud assy (5) with the spacers (20) to the support assemblies (95, 105) with the fasteners (115). (10) Installation of the toilet seat assy (40) (a) Install the unpainted toilet cover (65) to the unpainted toilet seat (50) with the unpainted fasteners (75, 80).

PAGE 708 SEP 23/09 25-41-01



1 Install the sealing (55) to the unpainted toilet seat (50). 2 Install the sealing (70) to the unpainted toilet cover (65). (b) Install the toilet seat assy (40) to the toilet shroud assy (5) with the the gaskets (85) and the unpainted nuts (90). J. Assembly of the Bi-Folding Door Assy (Refer IPL, Fig 8) (1) Install the kick strips (120, 125) to the bi-folding door assy. (2) Install the push plates (225). (3) Lock assy (175) (a) Install the knob (195) and the bracket (185) to the plate (180). (b) Install the spring (200) and the bolt (190) to the bracket (185). (4) Install the lock assy (175) to the upper part of the door plate with the countersunk screws (205). (5) Install the bushing (170) with the countersunk screws (60). (6) Hinge (70) (a) Install the setscrew (71) to the hinge (70). (7) Install the hinge (70) with the setscrews (71) and the profile (25) to the door plate with the countersunk screws (15). (8) Install the hinge (70) with the setscrews (71) and the profiles (10, 30) to the door plate with the countersunk screws (75). (9) Install the bumpers (220) to the stops (165). (10) Install the stops (165) to the hinge (70) with the countersunk screws (75). (11) Install the air grids (110) to the bi-folding door assy with the pan-head screws (115). (12) Install the grip (135) and the folding door handle (130) with the countersunk screws (140).

PAGE 709 SEP 23/09 25-41-01



(13) Door lock assy (315) (a) Install the lock (320) to the bi-folding door assy with the countersunk screws (60). (b) Install the escutcheon (325) with the s

Documents

COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED …manuals.amerijet.com/digidoc/AsIs/public/Mx... · A. This manual is written to the ATA specification 100. B. The manual describes