30-11-76

COMPONENT MAINTENANCE MANUAL COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST DUAL DISTRIBUTOR VALVE Part Number B03AA1040 B03AA1040 Amdt. B03AA1040 Amdt. B03AA1040 Amdt. B03AA1040 Amdt. B03AA1040 Amdt. B03AA1040 Amdt. B03AA1060 B03AA1060 Amdt. B03AA1060 Amdt. A B C D E F A B LIEBHERR-AEROSPACE TOULOUSE SAS (F1958) 408, Avenue des Etats-Unis - B.P.52010 31016 TOULOUSE CEDEX - FRANCE Phone: +33 (0)5.61.35.28.28 Fax: +33 (0)5.61.35.29.29 techpub.toulouse@liebherr.com Initial Issue: Mar 15/95 30-11-76 TP1 Revision No. 5 Jul 01/07 COMPONENT MAINTENANCE MANUAL Copyright ©2004 Liebherr-Aerospace Toulouse SAS This document is given in confidence and may not be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Liebherr-Aerospace Toulouse SAS. Unless Liebherr-Aerospace Toulouse SAS (the company) has accepted a contractual obligation in respect of the information and data contained herein, such information and data is provided without responsability and the company disclaim all liability arising from its use. Initial Issue: Mar 15/95 30-11-76 TP2 Revision No. 5 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series LIEBHERR-AEROSPACE TOULOUSE SAS (F1958) 408, Avenue des Etats-Unis - B.P.52010 31016 TOULOUSE CEDEX - FRANCE Phone: +33 (0)5.61.35.28.28 Fax: +33 (0)5.61.35.29.29 techpub.toulouse@liebherr.com REVISION TRANSMITTAL LETTER TO HOLDERS OF COMPONENT MAINTENANCE MANUAL FOR DUAL DISTRIBUTOR VALVE ATA 30-11-76. The revision No. 5, dated Jul 01/07 is attached and covers all components held by every operator. FILING INSTRUCTIONS: – THIS IS A COMPLETELY REISSUED CMM: • Remove and destroy the previous CMM, • File the new complete reissue CMM. – Affected pages are listed on the “LIST OF EFFECTIVE PAGES”, – File the REVISION TRANSMITTAL LETTER separately. 30-11-76 TL Page 1 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 TL Page 2 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series HIGHLIGHTS Revision No.5 - Jul 01/07 Pages which have been added, revised or deleted are outlined below together with the Highlights of the Revision. LOCATIONS DESIGNATION TITLE PAGE R LIST OF EFFECTIVE PAGES R DESCRIPTION OF CHANGE DISASSEMBLY TASK 30-11-76-040-801-A01 R Modified tool T04 ASSEMBLY TASK 30-11-76-420-802-A01 R Modified tool T04 SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES TASK 30-11-76-940-801-A01 R Tool M65724394 or 540260 become M65725780 GRAPHIC 30-11-76-991-021-A01 R Modified graphic of the tool T04 30-11-76 HLTS Page 1 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 HLTS Page 2 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series RECORD OF REVISIONS INSERTED REV. No. ISSUE DATE DATE BY INSERTED REV. No. ISSUE DATE 30-11-76 DATE BY ROR Page 1 Mar 15/95 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 ROR Page 2 Mar 15/95 COMPONENT MAINTENANCE MANUAL B03AA Series RECORD OF TEMPORARY REVISIONS INSERTED TEMP REV. No. ISSUE DATE REMOVED PAGE No. DATE BY DATE BY 30-11-76 RTR Page 1 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 RTR Page 2 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series SERVICE BULLETIN SERVICE BULLETIN INCORPORATION INTO CMM TITLE Number Rev Date Rev B03AA-30-04 00 Sep 18/98 02 - Improvement of the coil insulation resistance of the solenoid valve B03AA-30-05 00 Sep 03/04 03 - Protection of heating function connector pins for PNR B03AA1040. - Evacuation of the condensed water. - Standardization of cover for PNR B03AA1060 B03AA-30-06 00 Sep 03/04 03 - Tightness improvement of A and B control channels plugs - Improvement of hardware locking B03AA-30-07 00 Sep 03/04 03 - Standardization of the coil wires for the solenoid valves B03AA-30-08 00 Sep 03/04 03 - Improvement of pressure switch B03AA-30-09 00 Jun 01/06 04 - Replacement of the pressure switches 30-11-76 SBL Page 1 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 SBL Page 2 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series LIST OF EFFECTIVE PAGES SUBJECT PAGE DATE SUBJECT PAGE DATE 10 TITLE PAGE 1 2 R R Jul 01/07 Jul 01/07 RECORD OF REVISIONS 1 Mar 15/95 2 Blank Mar 15/95 RECORD OF TEMPORARY REVISIONS 1 Sep 03/04 2 Blank Sep 03/04 SERVICE BULLETIN LIST 1 Jun 01/06 2 Blank Jun 01/06 LIST OF EFFECTIVE PAGES 1 R 2 R 3 R 4 Blank Jul Jul Jul Jul 01/07 01/07 01/07 01/07 TABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 10 Blank Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 LIST OF ILLUSTRATIONS 1 2 Sep 03/04 Sep 03/04 1 2 3 4 5 6 7 8 9 Sep Sep Sep Sep Sep Sep Sep Sep Sep INTRODUCTION 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 Sep 03/04 DESCRIPTION AND OPERATION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Blank Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 TESTING AND FAULT ISOLATION 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun Jun 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 DISASSEMBLY 3001 30-11-76 R Jul 01/07 LEP Page 1 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series LIST OF EFFECTIVE PAGES (Continued) SUBJECT PAGE 3002 3003 3004 3005 3006 3007 3008 3009 3010 DATE R R R R R R R R R Jul Jul Jul Jul Jul Jul Jul Jul Jul 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 CLEANING 4001 4002 4003 4004 4005 4006 4007 4008 4009 4010 4011 4012 Blank Sep Sep Sep Sep Sep Sep Sep Sep Sep Sep Sep Sep 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 03/04 5001 5002 5003 5004 5005 5006 Blank Jun Jun Jun Jun Jun Jun 01/06 01/06 01/06 01/06 01/06 01/06 6001 6002 6003 6004 6005 6006 6007 6008 Jun Jun Jun Jun Jun Jun Jun Jun 01/06 01/06 01/06 01/06 01/06 01/06 01/06 01/06 INSPECTION/CHECK REPAIR ASSEMBLY 7001 7002 7003 7004 7005 R R R R R Jul Jul Jul Jul Jul 01/07 01/07 01/07 01/07 01/07 SUBJECT PAGE DATE 7006 R Jul 01/07 7007 R Jul 01/07 7008 R Jul 01/07 7009 R Jul 01/07 7010 R Jul 01/07 7011 R Jul 01/07 7012 R Jul 01/07 7013 R Jul 01/07 7014 R Jul 01/07 7015 R Jul 01/07 7016 R Jul 01/07 7017 Blank Jul 01/07 7018 R Jul 01/07 7019 R Jul 01/07 7020 R Jul 01/07 7021 R Jul 01/07 7022 R Jul 01/07 7023 R Jul 01/07 7024 R Jul 01/07 7025 R Jul 01/07 7026 R Jul 01/07 7027 R Jul 01/07 7028 R Jul 01/07 7029 R Jul 01/07 7030 R Jul 01/07 7031 R Jul 01/07 7032 R Jul 01/07 7033 R Jul 01/07 7034 R Jul 01/07 7035 R Jul 01/07 7036 R Jul 01/07 7037 R Jul 01/07 7038 R Jul 01/07 7039 R Jul 01/07 7040 R Jul 01/07 7041 R Jul 01/07 7042 R Jul 01/07 7043 R Jul 01/07 7044 R Jul 01/07 7045 Blank Jul 01/07 7046 R Jul 01/07 7047 R Jul 01/07 7048 R Jul 01/07 7049 R Jul 01/07 7050 R Jul 01/07 7051 R Jul 01/07 7052 R Jul 01/07 7053 R Jul 01/07 30-11-76 LEP Page 2 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series LIST OF EFFECTIVE PAGES (Continued) SUBJECT PAGE 7054 7055 7056 DATE R R R Jul 01/07 Jul 01/07 Jul 01/07 FITS AND CLEARANCES 8001 8002 8003 8004 Blank Jun Jun Jun Jun SPECIAL TOOLS, FIXTURES, CONSUMABLES 9001 9002 9003 9004 9005 9006 9007 9008 9009 9010 9011 9012 Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 01/06 01/06 01/06 01/06 EQUIPMENT AND R R R R R R R R R R R R 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 STORAGE (INCLUDING TRANSPORTATION) 15001 Sep 03/04 15002 Sep 03/04 APPENDIX A A-1 Jun 01/06 A-2 Jun 01/06 A-3 Jun 01/06 A-4 Blank Jun 01/06 A-5 Jun 01/06 A-6 Jun 01/06 APPENDIX B B-1 Sep 03/04 B-2 Blank Sep 03/04 ILLUSTRATED PARTS LIST 10001 R Jul 01/07 10002 Blank Jul 01/07 INTRO IPL 10003 10004 R R Jul 01/07 Jul 01/07 SUBJECT PAGE DATE 10005 R 10006 R 10007 R 10008 R 10009 R 10010 Blank Jul Jul Jul Jul Jul Jul 01/07 01/07 01/07 01/07 01/07 01/07 Jul Jul Jul Jul Jul Jul Jul Jul 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 ALPHA/NUMERIC INDEX 10011 10012 10013 10014 10015 10016 10017 10018 R R R R R R R R OPTIONAL VENDOR INDEX 10019 R Jul 01/07 10020 Blank Jul 01/07 DETAILED PARTS LIST 10021 10022 10023 10024 10025 10026 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036 10037 10038 10039 10040 10041 10042 10043 10044 10045 10046 30-11-76 R R R R R R R R Blank R R R R R Blank R R R R R Blank R R R R Blank Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul Jul 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 01/07 LEP Page 3 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 LEP Page 4 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS PAGE INTRODUCTION .............................................................................................................................. 1. Introduction ............................................................................................................................... A. General .............................................................................................................................. B. How to Use the Manual ...................................................................................................... C. Related Publications .......................................................................................................... D. CMM Page Blocks ............................................................................................................. E. Measurements ................................................................................................................... F. Units of Measure ................................................................................................................ G. Measurement Conversion Table ........................................................................................ H. Temperature Conversion Table .......................................................................................... I. Abbreviations ..................................................................................................................... J. Geometric Tolerance Symbols ........................................................................................... K. Verifications ........................................................................................................................ INTRO 1 INTRO 1 INTRO 1 INTRO 1 INTRO 1 INTRO 2 INTRO 5 INTRO 6 INTRO 7 INTRO 9 INTRO 9 INTRO 10 INTRO 10 DESCRIPTION AND OPERATION .................................................................................................. 1. Description ................................................................................................................................ A. General Description ........................................................................................................... B. Data ................................................................................................................................... 2. Detailed Description ................................................................................................................. 3. Operation .................................................................................................................................. 1 1 1 1 9 12 TESTING AND FAULT ISOLATION ................................................................................................. 1. Testing Procedure ..................................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Visual Inspection ......................................................................................................... (2) Electrical Continuity Test ............................................................................................. (3) Electrical Circuit Test .................................................................................................. (4) Functional Test of the Pressure Switches ................................................................... (5) Functional Test ............................................................................................................ E. Close-up ............................................................................................................................. 2. Testing Procedure ..................................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Visual Inspection ......................................................................................................... (2) Electrical Continuity Test ............................................................................................. (3) Electrical Circuit Test .................................................................................................. (4) Functional Test ............................................................................................................ E. Close-up ............................................................................................................................. 1001 1001 1001 1001 1002 1002 1002 1002 1003 1005 1005 1006 1008 1008 1008 1009 1009 1009 1009 1010 1012 1012 30-11-76 TOC Page 1 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE 3. 4. Fault Isolation ............................................................................................................................ A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Fault Isolation Procedure ................................................................................................... E. Close-up ............................................................................................................................. Fault Isolation ............................................................................................................................ A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Fault Isolation Procedure ................................................................................................... E. Close-up ............................................................................................................................. SCHEMATIC AND WIRING DIAGRAMS ........................................................................ NOT APPLICABLE DISASSEMBLY ................................................................................................................................ 1. Disassembly of the Dual Distributor Valve (01-001) .................................................................. A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Removal of the Connectors (01-040), (01-060), (01-080) and the Cover (01-010) .... (2) Removal of the Pressure Switches (01-180) .............................................................. (3) Removal of the Plate (01-200) ................................................................................... (4) Removal of the Pressure Relief Valve (01-270) and the Solenoid Valves .................. E. Close-up ............................................................................................................................. 2. Disassembly of the Equipped Body S/A (02-001) ..................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... (1) Preliminary Operation ................................................................................................. D. Procedure .......................................................................................................................... (1) Removal of the Nozzle S/A (02-210) .......................................................................... (2) Removal of the Nozzle S/A (02-210B) ........................................................................ (3) Removal of the Dual Valves ........................................................................................ E. Close-up ............................................................................................................................. 3. Disassembly of the Dual Distributor Valve (01A-001) ............................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Removal of the Connectors (01A-060) and (01A-080) and the Cover (01A-010) ....... (2) Removal of the Threaded Plugs (01A-170) and the Plate (01A-200) ......................... (3) Removal of the Pressure Relief Valve (01A-270) and the Solenoid Valves ................ E. Close-up ............................................................................................................................. 30-11-76 1014 1014 1014 1014 1014 1017 1018 1018 1018 1018 1019 1020 3001 3001 3001 3001 3001 3001 3001 3002 3002 3002 3003 3004 3004 3004 3004 3004 3004 3004 3004 3005 3005 3006 3006 3006 3006 3006 3006 3008 3008 3008 TOC Page 2 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE 4. Disassembly of the Equipped Body S/A (02A-001) ................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... (1) Preliminary Operation ................................................................................................. D. Procedure .......................................................................................................................... (1) Removal of the Nozzle S/A (02A-210) ........................................................................ (2) Removal of the Nozzle S/A (02A-210B) ..................................................................... (3) Removal of the Dual Valves ........................................................................................ E. Close-up ............................................................................................................................. 3009 3009 3009 3009 3009 3009 3009 3009 3010 3010 CLEANING ....................................................................................................................................... 1. External Cleaning of a Unit ....................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... (1) Preparation of the Unit ................................................................................................ D. Procedure .......................................................................................................................... (1) External Cleaning of the Unit ...................................................................................... E. Close-up ............................................................................................................................. 2. Cleaning of a Sub-Assembly ..................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Cleaning of the Sub-Assembly ................................................................................... E. Close-up ............................................................................................................................. 3. Cleaning of Component Parts ................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Cleaning of the Component Parts ............................................................................... E. Close-up ............................................................................................................................. 4. Cleaning Procedure .................................................................................................................. A. Cleaning ProcedureTable ................................................................................................... 5. Procedure 1: Heavy Alkaline Cleaning ..................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... (1) Material Preparation ................................................................................................... D. Procedure .......................................................................................................................... (1) Cleaning ...................................................................................................................... E. Close-up ............................................................................................................................. 4001 4001 4001 4001 4001 4001 4001 4001 4001 4002 4002 4002 4002 4002 4002 4002 4003 4003 4003 4003 4003 4003 4003 4004 4004 4005 4005 4005 4005 4005 4005 4005 4006 30-11-76 TOC Page 3 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE 6. Procedure 2: Cleaning with Solvents by the Dipping or the Spraying Procedure ..................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Cleaning with Solvents ............................................................................................... E. Close-up ............................................................................................................................. Procedure 3: Light Alkaline Cleaning ........................................................................................ A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... (1) Preparation ................................................................................................................. D. Procedure .......................................................................................................................... (1) Cleaning ...................................................................................................................... E. Close-up ............................................................................................................................. Procedure 4: Cleaning of Parts with an Alcohol-Based Cleaning Agent ................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Cleaning ...................................................................................................................... E. Close-up ............................................................................................................................. 4007 4007 4007 4007 4008 4008 4008 4009 4009 4009 4009 4009 4009 4009 4010 4011 4011 4011 4011 4011 4011 4011 INSPECTION/CHECK ...................................................................................................................... 1. Checking Procedure .................................................................................................................. A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Visual Inspection of Parts ........................................................................................... (2) Special Checks ........................................................................................................... E. Close-up ............................................................................................................................. 5001 5001 5001 5001 5001 5001 5001 5001 5005 REPAIR ............................................................................................................................................ 1. REPAIR No. 1: Corrosion Protection ........................................................................................ A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... (1) Removal of the Corrosion .......................................................................................... (2) Preparation of the Solution for Alochrome Treatment ................................................. D. Procedure .......................................................................................................................... (1) Alochrome Treatment ................................................................................................. E. Close-up ............................................................................................................................. 6001 6001 6001 6001 6001 6001 6001 6001 6001 6002 7. 8. 30-11-76 TOC Page 4 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE 2. REPAIR No. 2: Electrical Bonding ............................................................................................ A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Electrical Bonding Operation ...................................................................................... E. Close-up ............................................................................................................................. REPAIR No. 2: Electrical Bonding ............................................................................................ A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Electrical Bonding Operation ...................................................................................... E. Close-up ............................................................................................................................. 6003 6003 6003 6003 6003 6003 6003 6006 6006 6006 6006 6006 6006 6006 ASSEMBLY ...................................................................................................................................... 1. Assembly of the Dual Distributor Valve (01-001) ....................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Preparation of the Wiring ............................................................................................ (2) Assembly of the Solenoid Valves ................................................................................ (3) Preliminary Installation ................................................................................................ (4) Self-Opening Test of the Solenoid Valve .................................................................... E. Close-up ............................................................................................................................. 2. Test of the Solenoid Valve ......................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Functional Test of the Solenoid Valve ......................................................................... (2) Installation of the connector (01-040) ......................................................................... E. Close-up ............................................................................................................................. 3. Assembly of the Dual Valves ..................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Assembly of the Dual Valve ........................................................................................ E. Close-up ............................................................................................................................. 7001 7001 7001 7001 7002 7002 7002 7005 7008 7008 7008 7010 7010 7010 7011 7011 7011 7011 7012 7014 7014 7014 7014 7014 7014 7015 3. 30-11-76 TOC Page 5 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE 4. 5. 6. 7. 8. Assembly and Installation of the Nozzle S/A (02-210) and (02-210B) and the Heating Resistors (02-310), (1T), (2T) ................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Assembly of the Nozzle S/A ....................................................................................... (2) Assembly of the Nozzle S/A ....................................................................................... (3) Installation of the Nozzle S/A ...................................................................................... (4) Installation of the Nozzle S/A ...................................................................................... E. Close-up ............................................................................................................................. Installation of the Cover (02-040) and the Plate (01-200) ......................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Cover (02-040) ............................................................................... (2) Installation of the Plate (01-200) ................................................................................. E. Close-up ............................................................................................................................. Installation of the Pressure Switches and the Heating Resistors (01-140), (1P), (2P) .............. A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Pressure Switches (01-180) ........................................................... (2) Installation of the Heating Resistors (1P) and (2P) (01-140) ...................................... E. Close-up ............................................................................................................................. Installation of the Electrical wiring ............................................................................................. A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Electrical Wiring .............................................................................. (2) Installation of the Connectors (01-060) and (01-080) ................................................. E. Close-up ............................................................................................................................. Installation of the Pressure Relief Valve and the Cover (01-010) .............................................. A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Pressure Relief Valve .................................................................... (2) Installation of the Cover (01-010) ............................................................................... (3) Installation of the identification plate (01-450) on the cover (01-010) ......................... E. Close-up ............................................................................................................................. 30-11-76 7018 7018 7018 7018 7018 7018 7019 7019 7019 7020 7022 7022 7022 7022 7022 7022 7022 7023 7024 7024 7024 7024 7024 7024 7025 7025 7027 7027 7027 7027 7027 7027 7031 7031 7032 7032 7032 7032 7032 7032 7032 7033 7033 TOC Page 6 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE 9. 10. 11. 12. 13. 14. Assembly of the Dual Distributor Valve (01A-001) .................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Assembly of the Solenoid Valves ............................................................................... (2) Preliminary Installation ................................................................................................ (3) Self-Opening Test of the Solenoid Valve .................................................................... E. Close-up ............................................................................................................................. Test of the Solenoid Valve ......................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Functional Test of the Solenoid Valve ......................................................................... E. Close-up ............................................................................................................................. Assembly of the Dual Valves ..................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Assembly of the Dual Valve ........................................................................................ E. Close-up ............................................................................................................................. Assembly and Installation of the Nozzle S/A (02A-210) and (02A-210B) ................................. A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Assembly of the Nozzle S/A ....................................................................................... (2) Assembly of the Nozzle S/A ....................................................................................... (3) Installation of the Nozzle S/A ...................................................................................... (4) Installation of the Nozzle S/A ...................................................................................... E. Close-up ............................................................................................................................. Installation of the Cover (02A-040) and the Plate (01A-200) .................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Cover (02A-040) ............................................................................. (2) Installation of the Plate (01A-200) .............................................................................. E. Close-up ............................................................................................................................. Installation of the Threaded Plugs (01A-170) ............................................................................ A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Threaded Plugs (01A-170) ............................................................. E. Close-up ............................................................................................................................. 30-11-76 7034 7034 7034 7034 7035 7035 7037 7037 7037 7039 7039 7039 7040 7040 7040 7040 7042 7042 7042 7042 7042 7042 7043 7046 7046 7046 7046 7046 7046 7046 7047 7047 7047 7049 7049 7049 7049 7049 7049 7049 7050 7051 7051 7051 7051 7051 7051 7051 TOC Page 7 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE 15. Installation of the Electrical wiring ............................................................................................. A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Electrical Wiring .............................................................................. E. Close-up ............................................................................................................................. 16. Installation of the Pressure Relief Valve and the Cover (01A-010) ........................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Installation of the Pressure Relief Valve .................................................................... (2) Installation of the Cover (01A-010) ............................................................................. (3) Installation of the Identification Plate (01A-450) ......................................................... E. Close-up ............................................................................................................................. 7052 7052 7052 7052 7052 7052 7053 7055 7055 7055 7055 7055 7055 7055 7056 7056 FITS AND CLEARANCES ................................................................................................................ 1. Fits and Clearances .................................................................................................................. 2. Tightening Torques .................................................................................................................... A. Table of Tightening Torques ............................................................................................... 3. Tightening Torques .................................................................................................................... A. Table of Tightening Torques ............................................................................................... 8001 8001 8002 8002 8003 8003 SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES ............................................. 1. Special Tool, Fixtures and Equipment ....................................................................................... A. Special Tool Table .............................................................................................................. 2. Consumable Materials .............................................................................................................. A. Consumable Materials Table .............................................................................................. 9001 9001 9001 9010 9010 SPECIAL PROCEDURES ............................................................................................... NOT APPLICABLE REMOVAL ....................................................................................................................... NOT APPLICABLE INSTALLATION ............................................................................................................... NOT APPLICABLE SERVICING ..................................................................................................................... NOT APPLICABLE STORAGE (INCLUDING TRANSPORTATION) ............................................................................... 1. Storage ...................................................................................................................................... A. Reason for the Job ............................................................................................................. B. Job Set-up Information ....................................................................................................... C. Job Set-up .......................................................................................................................... D. Procedure .......................................................................................................................... (1) Packaging ................................................................................................................... (2) Storage ....................................................................................................................... (3) Destorage ................................................................................................................... (4) Transportation ............................................................................................................. E. Close-up ............................................................................................................................. 30-11-76 15001 15001 15001 15001 15001 15001 15001 15002 15002 15002 15002 TOC Page 8 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TABLE OF CONTENTS (Continued) PAGE REWORK (SERVICE BULLETIN ACCOMPLISHMENT PROCEDURES) ...................... NOT APPLICABLE APPENDIX A .................................................................................................................................... 1. Acceptance Test Repair Data Sheet (ATRDS) .......................................................................... A. Test Procedure ................................................................................................................... 2. Acceptance Test Repair Data Sheet (ATRDS) .......................................................................... A. Test Procedure ................................................................................................................... A-1 A-1 A-1 A-5 A-5 APPENDIX B .................................................................................................................................... 1. Approved Repairers .................................................................................................................. A. List of Approved Repairers ................................................................................................ B-1 B-1 B-1 ILLUSTRATED PARTS LIST ............................................................................................................ 1. Introduction ............................................................................................................................... A. General .............................................................................................................................. B. How to Use the Illustrated Parts List .................................................................................. C. Vendors List (VL) ............................................................................................................... D. Numerical Index (NI) .......................................................................................................... E. Detailed Parts List (DPL) ................................................................................................... F. Updating ............................................................................................................................. 10001 10003 10003 10003 10003 10003 10004 10006 VENDORS LIST ........................................................................................................................ 10008 Alpha/Numeric Index ................................................................................................................. 10011 Optional Vendor Index ............................................................................................................... 10018 Detailed Parts List ..................................................................................................................... 10021 30-11-76 TOC Page 9 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 TOC Page 10 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series LIST OF ILLUSTRATIONS FIGURE TITLE 1 2 3 4 5 6 7 8 9 10 11 12 1001 1002 1003 1004 5001 5002 6001 6002 6003 6004 7001 7002 Overall Dimensions (For PNR B03AA1040) ............................................................... Overall Dimensions (For PNR B03AA1060) ............................................................... Pneumatic and Electrical Connections - Electrical Diagram (For PNR B03AA1040) . Pneumatic and Electrical Connections - Electrical Diagram (For PNR B03AA1060) . Description (For PNR B03AA1040) ............................................................................ Description (For PNR B03AA1060) ............................................................................ Circuit A Depressurized and Circuit B Pressurized (For PNR B03AA1040) ............... Circuit A Pressurized and Circuit B Depressurized (For PNR B03AA1040) ............... Circuit A and Circuit B Depressurized (For PNR B03AA1040) ................................... Circuit A Depressurized and Circuit B Pressurized (For PNR B03AA1060) ............... Circuit A Pressurized and Circuit B Depressurized (For PNR B03AA1060) ............... Circuit A and Circuit B Depressurized (For PNR B03AA1060) ................................... Wiring Diagram (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) ........... Functional Test (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) ............ Wiring Diagram (For Types B03AA1060, B03AA1060 Amdt A and B) ....................... Functional Test (For Types B03AA1060, B03AA1060 Amdt A and B) ........................ Check of the nozzle (02-230B) ................................................................................... Check of the injector (02-240B) .................................................................................. Bonding Braids (For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) .............. Electrical Bonding (For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) ......... Bonding Braids (for PNR B03AA1060, B03AA1060 Amdt A, B) ................................. Electrical Bonding (For PNR B03AA1060, B03AA1060 Amdt A, B) ........................... Heating Resistances (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) ... Wiring Circuit of the Heating Circuit (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) ................................................................................................................... Preparation of the Core (01-350), Installation of the Coil (01-370) and Adjustment of the Diaphragm (01-360) .............................................................................................. Self-Opening Test of the Solenoid Valve ..................................................................... Test of the Solenoid Valve ........................................................................................... Assembly of the Dual Valves ...................................................................................... Assembly and Installation of the Nozzle S/A (02-210) and (02-210B) ........................ Installation of the Pressure Switches and the Heating Resistors (01-140), (1P), (2P) Installation of the electrical wiring ............................................................................... Preparation of the Core (01A-350), Installation of the Coil (01A-370) and Adjustment of the Diaphragm (01A-360) ....................................................................................... Self-Opening Test of the Solenoid Valve ..................................................................... Test of the Solenoid Valve ........................................................................................... Assembly of the Dual Valves ...................................................................................... Assembly and Installation of the Nozzle S/A (02A-210) and (02A-210B) ................... Installation of the Electrical Wiring .............................................................................. Special Tools ............................................................................................................... Special Tools ............................................................................................................... Special Tools ............................................................................................................... Special Tools ............................................................................................................... Special Tools ............................................................................................................... Special Tools ............................................................................................................... Special Tools ............................................................................................................... 7003 7004 7005 7006 7007 7008 7009 7010 7011 7012 7013 7014 7015 9001 9002 9003 9004 9005 9006 9007 PAGE 30-11-76 3 5 7 8 10 11 13 14 15 17 18 19 1004 1007 1011 1013 5003 5004 6004 6005 6007 6008 7003 7004 7007 7009 7013 7016 7021 7026 7029 7036 7038 7041 7044 7048 7054 9003 9004 9005 9006 9007 9008 9009 LOI Page 1 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series LIST OF ILLUSTRATIONS (Continued) FIGURE TITLE PAGE Detailed Parts List 01 01A 02 02A Dual Distributor Valve ................................................................................................. Dual Distributor Valve ................................................................................................. Equipped Body S/A ..................................................................................................... Equipped Body S/A ..................................................................................................... 30-11-76 10022 10030 10036 10042 LOI Page 2 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series INTRODUCTION TASK 30-11-76-871-801-A01 1. Introduction A. General (1) This component maintenance manual (CMM) agrees with the Air Transport Association (ATA) iSpec 2200. It is written in AECMA Simplified English (European Association of Aerospace Industries). (2) This CMM gives the procedures necessary to do easy checks and replacement of parts and components: it also gives the procedures for maintenance. The maintenance procedures given in this CMM are only for approved persons with the necessary skills. (3) This CMM gives the shop maintenance procedures for the component. (4) This manual uses the identification of the tasks and subtasks which is specified in the Maintenance Task Oriented Support System (MTOSS). The maintenance tasks and other data have special MTOSS numbers because the manual uses Electronic Data Processing (EDP). The user of the manual can ignore the MTOSS numbers. (5) This manual contains: – The technical data for the component – The maintenance and repair procedures for the component – An Illustrated Parts List (IPL) with the data for the component parts. The parts are identified in all the Page Blocks of the manual by the IPL Figure and the item number. (6) B. C. A check of DISASSEMBLY, TESTING and ASSEMBLY procedures was made in the workshop. How to Use the Manual (1) Make sure that the manual contains the applicable data for your component. Look for the part number on the Title Page. (2) To identify a part or to find a part number, refer to the IPL, which has an Introduction to show the procedure. (3) You must use the instructions in this manual for all the maintenance steps of a component. Read all the applicable WARNINGS and CAUTIONS before you do the work on the component. (4) When you use consumable materials, these materials are identified by a code number from a list in the Consumable Materials Table. (5) When you use special tools, these tools are identified by a code number which is in a list in the Special Tools Table. (6) For the tightening torque values of the parts, refer to the Table of Tightening Torques. Related Publications (1) Acceptance Test Repair Data Sheet (ATRDS) (a) The test operator uses this sheet to record the test values during the test steps. 30-11-76 INTRO Page 1 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series (2) List of Approved Repairers (LOAR) The issuer of this CMM is LIEBHERR-AEROSPACE. This document is in the appendix of this CMM. D. CMM Page Blocks (1) The data for each component in the CMM is divided into specific Page Blocks. Each Page Block has its specified subject matter and its specified page numbering. These Page Blocks have these titles: PAGE BLOCKS PAGE NUMBER Description and Operation 0001 to 0999 Testing and Fault Isolation 1001 to 1999 Schematics and Wiring Diagrams 2001 to 2999 Disassembly 3001 to 3999 Cleaning 4001 to 4999 Inspection/Check 5001 to 5999 Repair 6001 to 6999 Assembly 7001 to 7999 Fits and Clearances 8001 to 8999 Special Tools, Fixtures, Equipment and Consumables 9001 to 9999 Illustrated Parts List 10001 to 10999 Special Procedure 11001 to 11999 Not applicable Removal 12001 to 12999 Not applicable Installation 13001 to 13999 Not applicable Servicing 14001 to 14999 Not applicable Storage (including Transportation) 15001 to 15999 Rework (Service Bulletin Instructions) 16001 to 16999 (2) ACTUAL VERIFICATIONS DATE BY Not applicable Not applicable Description and Operation This Page Block gives general data. It gives a mechanical description and an electrical description. It gives a description of the configuration and operation of the component. 30-11-76 INTRO Page 2 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series (3) (4) Testing and Fault Isolation (a) It contains special tests and procedures which you must do to find the condition of a component. The general test procedure is given in the FAULT ISOLATION TABLE. For each test, this table refers to a special procedure which gives all the parameters which you must set. It also gives all the parameters for which you must do a check. (b) The pressure values in the tests are gage-pressure values. (c) Before you use a measuring instrument, make sure that it is in correct operating condition and that it is calibrated. (d) Do a check for pneumatic system tightness, if this is applicable. (e) You must do the tests in a room at ambient temperature: + 25 °C ± 20 °C (41 °F to 113 °F). Schematic and Wiring Diagrams This Page Block contains all the schematic diagrams and the wiring and interconnecting diagrams of the cards. It also contains the diagrams of: – Chassis wiring, modules, and sub-assemblies – External connector interconnections in the equipment. (5) Disassembly (a) This Page Block gives step-by-step disassembly instructions in a correct sequence: it refers to the figure item numbers from the IPL illustration(s), when they are applicable. Identify the type of fault to know how much disassembly is necessary (do this to prevent disassembly/reassembly work that is not necessary). The procedure given below is when full disassembly is necessary. (b) Put the component on a clean workbench, in a dust-free and moisture-free room. Move all the parts carefully, and prevent corrosion and impact damage to them after disassembly. NOTE: Always discard all the seals and gaskets during disassembly. Discard the washers, the nuts and the screws during disassembly if they are damaged. (6) (7) Cleaning (a) This Page Block gives a step-by-step description of the cleaning operations for the component and its parts. (b) Always use the recommended procedures for the component parts of the unit. Inspection / Check (a) This Page Block gives the full check procedures which are necessary during shop maintenance. (b) Discard all the defective parts if the document does not give a repair procedure. 30-11-76 INTRO Page 3 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series (c) (8) Do all the inspections/checks on the cleaned parts. Repair This Page Block contains the full repair procedures and specifications which are necessary to repair a worn or damaged part. As specified in the INSPECTION/CHECK section, you must reject the defective parts if the document does not give a repair procedure. Replace the defective parts with new parts. (9) (10) Assembly (a) This Page Block gives step-by-step assembly instructions in a correct sequence, which refer to the figure item numbers from the IPL illustration(s), if applicable. (b) Put the component on a clean workbench, in a dust-free and moisture-free room. More all the parts carefully, and prevent corrosion and impact damage to them. (c) Be sure to remove the storage protection coating from all the new parts before assembly. Clean the new part if necessary. Fits and Clearances (a) This Page Block gives a table and some figures which give the fits and clearances data and the torque values for assembly. It also gives the permitted wear for in-service / service, and the manufacturer’s design wear-tolerances. (b) Fits and Clearances Table (c) 1 The identifiers in column (1) show the location of the clearance or the dimension that you must measure. 2 The identifiers in column (2) identify the parts in the IPL (Figure + Item number). 3 Column (3) gives the initial manufacturing dimensions and clearances. 4 In-service Wear Limits (Columns 4). The maximum limits are the maximum wear limits. If the part is in these limits then it is serviceable. b If the parts have more wear than the specified limits, you must repair or replace them. Torque Values 1 (d) a All torque values in this manual are shown in the Table of Tightening Torques. The parts are identified by the figure number and the item number of the IPL. Spring Data 1 The technical data for all springs used in the unit are shown in the Table of Spring Data. The parts are identified by the figure number and the item number of the IPL. 30-11-76 INTRO Page 4 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series (11) (12) Special Tools, Fixtures, Equipment and Consumables (a) This Page Block shows all the special tools, the fixtures, the equipment and the consumables which are necessary to do the maintenance actions (which are given in the other page blocks). (b) All the items shown are identified in this manual by a standard code number: Txx for Tools, Fixtures and Equipment and Mxx for Consumable Materials. Illustrated Parts List This Page Block contains the full list of all the parts of the component (For the detailed description, refer to the IPL INTRO). (13) Special Procedures This Page Block contains tasks which are given in other Page Blocks of the manual, but which are necessary because of other maintenance tasks. The tasks are self-contained repairs or preventive maintenance. (14) Removal This Page Block gives the procedure for the removal of modules/sub-assemblies from complex modular components. (15) Installation This Page Block gives the procedure for the installation of modules/sub-assemblies in complex modular components. (16) Servicing This Page Block gives the self-contained tasks which are necessary because of other maintenance tasks. (17) Storage This Page Block gives the requirements for preparation for transportation, for special handling, for packaging, for storage and for preservation: these requirements are for the component after assembly or test. (18) Rework This Page Block gives the rework procedures which are necessary for in-service components. E. Measurements (1) The measurements which are given in this manual come from the original manufacturing drawings. (2) This CMM uses the “Systeme International” (S.I.) units for quantities and values. It also gives the imperial units in parentheses. 30-11-76 INTRO Page 5 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series F. Units of Measure (1) (2) S.I. Units A Ampere bar Bar daN.m Decanewton meter g Gram g/min Gram per minute g/mm Gram per millimeter g/s Gram per second Hz Hertz l/min Liter per minute l/h Liter per hour mbar Millibar min Minute m³ Cubic meter N Newton N.m Newton meter Nl Liter in standard conditions: Temperature = 0 °C (32 °F) Pressure = 1013,2 hPa (14.691 psi) Pa Pascal rpm Revolution per minute s Second W Watt °C Degree Celsius Ω Ohm U.S. Units cu Cubic cu.ft/min foot per minute in standard conditions: Temperature = 20 °C (68 °F) Pressure = 1013,2 hPa (14.691 psi) cu.in Cubic inch 30-11-76 INTRO Page 6 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series (3) ft Foot gr Grain gr/lb Grain per pound in Inch lb Pound lb/min Pound per minute lbf.in Pound force inch oz Ounce psi Pound per square inch psia Absolute pressure in pounds per square inch psig Relative pressure in pounds per square inch °F Degree Fahrenheit Multiplying Prefixes p Pico d Deci n Nano da Deca µ Micro h Hecto m Milli k Kilo c Centi M Mega G. Measurement Conversion Table (1) From SI Measurement to U.S. Standard System 1 kPa 0.1450 psi 1 cm 0.3937 in 1 cm² 0.1550 in² 1 mbar 0.0145 psi 30-11-76 INTRO Page 7 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series (2) 1N 0.2248 lbf 1g 0.0353 oz 1 kg 2.2046 lb 1 kg/min 2.2046 lb/min 1l 0.2642 gal (u.s.) 1l 0.0353 cu.ft 1 l/min 0.2642 gal(u.s.)/min 1 l/min 0.0353 cu.ft/min 1 mm 0.0394 in 1 N.m 8.8507 lbf.in 1 N.m 0.7376 lbf.ft From U.S. Standard System to SI Measurement 1 cu.ft/min 28,317 l/min 1 psi 6,8948 kPa 1 psi 69 mbar 1 in 2,54 cm 1 in 25,4 mm 1 in² 6,4516 cm² 1 lbf 4,4482 N 1 oz 28,3495 g 1 inHg 3,3864 kPa 1 lb 0,4536 kg 1 lb/min 0,4536 kg/min 1 gal (U.S.) 3,7854 l/min 1 lbf.in 0,1130 N.m 1 lbf.ft 1,3558 N.m 30-11-76 INTRO Page 8 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series H. Temperature Conversion Table SI MEASUREMENT Degrees Celsius (°C) Degrees °C = (°F - 32) x 0.5555 I. U.S. STANDARD SYSTEM Degrees Fahrenheit (°F) Degrees °F = (°C x 1.8000) + 32 Abbreviations abs. Absolute ATA Air Transport Association of America CMM Component Maintenance Manual dia. Diameter Fig. Figure HP High Pressure ID Inner Diameter IP Intermediate Pressure IPL Illustrated Parts List LP Low Pressure max. Maximum Mfr Manufacturer min. Minimum MTOSS Maintenance Task Oriented Support System No Number OD Outer Diameter PNR Part Number para. Paragraph Ref. Refer to rel. Relative S/A Sub-Assembly SB Service Bulletin SIL Service Information Letter TBD To be defined 30-11-76 INTRO Page 9 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series J. VAC Volt alternating current VDC Volt direct current % Percent Geometric Tolerance Symbols (1) K. The symbols agree with the NFE04-552, NFE05-016 and ISO1101 specifications. Verifications (1) The functions (tasks) which are given in this manual were verified by simulation. This component maintenance manual is "shop verified" after all the functions (tasks) are actually done on the equipment. (2) This statement is revised after all verifications are done. (3) The list of Page Blocks gives the shop verifications which are actually done. We will revise this statement after all verifications are made. 30-11-76 INTRO Page 10 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series DESCRIPTION AND OPERATION TASK 30-11-76-872-801-A01 1. Description A. General Description For PNR B03AA1040 The heated dual distributor valve has two assemblies that operate independently. They pressurize, one after the other, two sets of de-icer chambers through the excitation of the related solenoid valve (channels A and B). The jet pump supplies a negative pressure which causes the two sets of de-icer chambers to close when the related solenoid valves are de-energized. The internal heating system supplies a positive ambient temperature for the solenoid valve, the jet pump and the pressure detection functions on the channels A and B (pressure switch). For PNR B03AA1060 The dual distributor valve of the engine nacelle has two assemblies that operate independently. They pressurize, one after the other, two sets of de-icer chambers through the excitation of the related electro-magnet. The jet pump supplies a negative pressure which causes the two sets of de-icer chambers to close when the related electro-magnet is not supplied. B. Data (1) Physical Data – Weight: ≤ 1,2 kg (2.64 lb) (for all types) – Overall dimensions: (Ref. Fig. 1 for PNR B03AA1040) (Ref. Fig. 2 for PNR B03AA1060) (2) Technical Data (a) Attachment: by a plate with three holes dia. 6,5 mm (0.26 in). (b) Connection: (Ref. Fig. 3 for PNR B03AA1040) (Ref. Fig. 4 for PNR B03AA1060) – Supply: one embossment MS33649-12. – Utilization: two embossments MS33649-10. – Electrical connectors: NAS1599 (for PNR B03AA1040) EN2997 (for PNR B03AA1000) 30-11-76 Page 1 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series (c) Electrical supply: – 28 VDC – 115 VAC - 400 Hz (d) Release pressure of the pressure switch (for PNR B03AA1040 only): – Between 1070 and 1260 mbar (15.52 to 18.27 psi). (e) Operating temperature T° ≤ 150 °C (302 °F) for a supply pressure of 1400 ± 10 mbar (20.16 to 20.45 psi). 30-11-76 Page 2 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 60,25 mm (2.372 in) 12,5 mm (0.492 in) 12,5 mm (0.492 in) KEY POSITION A IDENTIFICATION NAME PLATE LTS F1958 LIEBHERR TOULOUSE DUAL DISTRIBUTOR VALVE P/N S/N B03AA1040 DATE 6884501700 INSP AMDT A E B F INSP C D F1958 LIEBHERR TOULOUSE A B A 118 mm (4.645 in) B 61,2 mm (2.409 in) 3 SPOTFACINGS Ø 16 mm (Dia. 0.630 in) A PROTECTIVE CAPS PROTECTIVE CAP 139,5 mm max. (5.492 in max.) PROTECTIVE CAP 22 mm max. (0.866 in max.) 82 mm (3.228 in) at013b01.cgm B Overall Dimensions (For PNR B03AA1040) (Sheet 1 of 2) Figure 1/GRAPHIC 30-11-76-991-001-A01 30-11-76 Page 3 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series B 44 mm (1.732 in) = A B 36 mm (1.417 in) = 3 ATTACHMENT HOLES + 0,2 Ø 6,5 0 mm (Dia. 0.256 to 0.263 in) at014b01.cgm 22 mm (0.866 in) 120 mm (4.724 in) 46 mm (1.811 in) 84 mm (3.307 in) Overall Dimensions (For PNR B03AA1040) (Sheet 2 of 2) Figure 1/GRAPHIC 30-11-76-991-001-A01 30-11-76 Page 4 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 12,5 mm (0.492 in) 12,5 mm (0.492 in) KEY POSITION A IDENTIFICATION NAME PLATE LTS F1958 LIEBHERR TOULOUSE DUAL DISTRIBUTOR VALVE F1958 LIEBHERR TOULOUSE P/N S/N B03AA1060 DATE 6884501600 INSP INSP AMDT A B A B A LOCKWIRE 118 mm (4.645 in) B 61,2 mm (2.409 in) 3 SPOTFACINGS Ø 16 mm (Dia. 0.630 in) A 139,5 mm max. (5.492 in max.) PROTECTIVE CAP PROTECTIVE CAPS 82 mm (3.228 in) at015a01.cgm B Overall Dimensions (For PNR B03AA1060) (Sheet 1 of 2) Figure 2/GRAPHIC 30-11-76-991-001-B01 30-11-76 Page 5 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series B 44 mm (1.732 in) = A B 36 mm (1.417 in) = 3 ATTACHMENT HOLES + 0,2 Ø 6,5 0 mm (Dia. 0.256 to 0.263 in) at016b01.cgm 22 mm (0.866 in) 120 mm (4.724 in) 46 mm (1.811 in) 84 mm (3.307 in) Overall Dimensions (For PNR B03AA1060) (Sheet 2 of 2) Figure 2/GRAPHIC 30-11-76-991-001-B01 30-11-76 Page 6 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series PNEUMATIC CONNECTIONS MS33649-12 PROTECTIVE PLUG S693-11612UNF3A ELECTRICAL CONNECTOR (PW) (6 PIN CONTACTS) NAS1599 ELECTRICAL CONNECTOR (PN) (6 PIN CONTACTS) NAS1599 PNEUMATIC CONNECTIONS MS33649-10 PROTECTIVE PLUG S693-7814UNF3A ELECTRICAL CONNECTOR (3 PIN CONTACTS) NAS1599 OPERATING ELECTRICAL DIAGRAM HEATING ELECTRICAL DIAGRAM A B A B C SOLENOID VALVE PRESSURE SWITCH SOLENOID VALVE SOLENOID VALVE ELECTRICAL CONNECTOR (PW) SOLENOID VALVE PRESSURE SWITCH at017a01.cgm A B C D E F PRESSURE SWITCH A B C D E F NOZZLE ELECTRICAL CONNECTOR (PN) Pneumatic and Electrical Connections - Electrical Diagram (For PNR B03AA1040) Figure 3/GRAPHIC 30-11-76-991-002-A01 30-11-76 Page 7 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series PNEUMATIC CONNECTIONS MS33649-12 PROTECTIVE PLUG S693-11612UNF3A ELECTRICAL CONNECTOR (5 PIN CONTACTS) EN2997-ORS10-05P6 ELECTRICAL CONNECTOR (5 PIN CONTACTS) EN2997-ORS10-05PN PNEUMATIC CONNECTIONS MS33649-10 PROTECTIVE PLUG S693-7814UNF3A OPERATING ELECTRICAL DIAGRAM A ELECTRICAL CONNECTOR (PN) 1 2 3 4 5 SOLENOID VALVE B ELECTRICAL CONNECTOR (P6) SOLENOID VALVE at018a01.cgm 1 2 3 4 5 Pneumatic and Electrical Connections - Electrical Diagram (For PNR B03AA1060) Figure 4/GRAPHIC 30-11-76-991-002-B01 30-11-76 Page 8 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-872-802-A01 2. Detailed Description A. For PNR B03AA1040 (Ref. Fig. 5) The primary components of this equipment are: (1) A molded composite-material body (1) and cover (2). The markings “A” and “B” on the two “utilization” outlets of the cover identify the chambers. (2) Two dual valves attached between the body (1) and the cover (2) to close the chambers. (3) A pressure relief valve (3). (4) Two solenoid valves (4) connected to the electrical connectors (5) and (6). (5) Two pressure switches (7) connected to the electrical connectors (5) and (6). (6) A depressurization jet-pump assembly (8). NOTE: Two heating resistors are installed in the pressure switches (7) and the jet pump (8). The heating system is connected to the electrical connector (9). (7) B. A plate (10) installed on the body (1) with five screws. For PNR B03AA1060 (Ref. Fig. 6) (1) A molded composite-material body (1) and cover (2). The markings “A” and “B” on the two “utilization” outlets of the cover identify the chambers. (2) Two dual valves attached between the body (1) and the cover (2) to close the chambers. (3) A pressure relief valve (3). (4) Two solenoid valves (4) connected to the electrical connectors (5) and (6). (5) A depressurization jet-pump assembly (8). (6) A plate (9) installed on the body (1) with five screws. (7) A spacer (10) installed between the connectors (5) and (6) and the cover (2). (8) A blanking plate (11) attached with four screws. 30-11-76 Page 9 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series SOLENOID VALVE (4) PRESSURE RELIEF VALVE (3) COVER (2) SOLENOID VALVE (4) CONNECTOR (5) CONNECTOR (6) JET PUMP (8) PLATE (10) CONNECTOR (9) LOCKWIRE BODY (1) at019a01.cgm PRESSURE SWITCH (7) Description (For PNR B03AA1040) Figure 5/GRAPHIC 30-11-76-991-003-A01 30-11-76 Page 10 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series SOLENOID VALVE (4) PRESSURE RELIEF VALVE (3) COVER (2) SPACER (10) SOLENOID VALVE (4) CONNECTOR (5) CONNECTOR (6) JET PUMP (8) PLATE (9) PLATE (11) LOCKWIRE at020a01.cgm BODY (1) Description (For PNR B03AA1060) Figure 6/GRAPHIC 30-11-76-991-003-B01 30-11-76 Page 11 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-873-801-A01 3. Operation A. For PNR B03AA1040 (Ref. Fig. 7, Ref. Fig. 8 and Ref. Fig. 9) The dual distributor valve inflates and deflates the de-icer group. In the different icing conditions, an electronic timer controls the operation of this unit through different cycles (quick, slow ...). At the start of the de-icing cycle: – The de-energized solenoid valve A (9) is closed. – The inflation valve A (4) is closed. – The supply pressure and the spring (7) move the inflation valve A (4) to its seat. In this position, the deflation valve A (2) is open and connects the de-icer to the jet-pump suction port. The circuit A is depressurized (Ref. Fig. 7). The timer controls the energization of the solenoid valve B (10) which vents the air chamber B (11) installed above the diaphragm (12). Then, the pressure on the other face of the diaphragm opens the inflation valve B (14) and closes the deflation valve B (15). In this position, the circuit B is pressurized (Ref. Fig. 7). When the solenoid valve B (10) is de-energized, the chamber B (11) closes again and the pressure on each face of the diaphragm is balanced through the calibrated nozzle (13). The inflation valve B (14) closes while the deflation valve B (15) opens. The de-icer is depressurized quickly through the relief valve (16). The jet pump (3) depressurizes the de-icer (negative pressure). In this position, the circuit B is depressurized (Ref. Fig. 8). At the same time, the air vent chamber A (8), installed above the diaphragm A (6), is vented after the solenoid valve A (9) of the circuit “A” is energized. The pressure on the other face of the diaphragm opens the inflation valve A (4) and closes the deflation valve A (2). In this position, the circuit A is pressurized (Ref. Fig. 8). The different operating cycles of the timer give the conditions that follow: – Circuit A depressurized, circuit B pressurized (Ref. Fig. 7) (during 5 s). – Circuit A pressurized, circuit B depressurized (Ref. Fig. 8) (during 5 s). – Circuits A and B depressurized (usually when the de-icing system is not in operation) (Ref. Fig. 9). (1) Negative-pressure jet pump (3) The jet pump depressurizes the two circuits. It includes an injector and a nozzle. (2) Pressure switches (5) The pressure switches operate when the pressure increases. They are installed in the body and attached with screws to the utilization circuit connector connected to the de-icers. 30-11-76 Page 12 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 3 4 5 6 7 8 SUPPLY DEPRESSURE 2 A 1 9 16 10 B 15 PRESSURE 14 13 5 12 11 KEY CHAMBER 7 SPRING 13 NOZZLE 2 DEFLATION VALVE A 8 CHAMBER A 14 INFLATION VALVE B 3 JET PUMP 9 SOLENOID VALVE A 15 DEFLATION VALVE B 4 INFLATION VALVE A 10 SOLENOID VALVE B 16 PRESSURE RELIEF VALVE 5 PRESSURE SWITCH 11 CHAMBER B A CIRCUIT A 6 DIAGRAM A 12 DIAGRAM B B CIRCUIT B at021b01.cgm 1 Circuit A Depressurized and Circuit B Pressurized (For PNR B03AA1040) Figure 7/GRAPHIC 30-11-76-991-004-A01 30-11-76 Page 13 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 3 4 5 6 7 8 SUPPLY PRESSURE 2 A 1 9 16 10 B 15 DEPRESSURE 14 13 5 12 11 KEY CHAMBER 7 SPRING 13 NOZZLE 2 DEFLATION VALVE A 8 CHAMBER A 14 INFLATION VALVE B 3 JET PUMP 9 SOLENOID VALVE A 15 DEFLATION VALVE B 4 INFLATION VALVE A 10 SOLENOID VALVE B 16 PRESSURE RELIEF VALVE 5 PRESSURE SWITCH 11 CHAMBER B A CIRCUIT A 6 DIAGRAM A 12 DIAGRAM B B CIRCUIT B at023b01.cgm 1 Circuit A Pressurized and Circuit B Depressurized (For PNR B03AA1040) Figure 8/GRAPHIC 30-11-76-991-005-A01 30-11-76 Page 14 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 3 4 5 6 7 8 SUPPLY DEPRESSURE 2 A 1 9 16 10 B 15 PRESSURE 14 13 5 12 11 KEY CHAMBER 7 SPRING 13 NOZZLE 2 DEFLATION VALVE A 8 CHAMBER A 14 INFLATION VALVE B 3 JET PUMP 9 SOLENOID VALVE A 15 DEFLATION VALVE B 4 INFLATION VALVE A 10 SOLENOID VALVE B 16 PRESSURE RELIEF VALVE 5 PRESSURE SWITCH 11 CHAMBER B A CIRCUIT A 6 DIAGRAM A 12 DIAGRAM B B CIRCUIT B at025b01.cgm 1 Circuit A and Circuit B Depressurized (For PNR B03AA1040) Figure 9/GRAPHIC 30-11-76-991-006-A01 30-11-76 Page 15 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series B. For PNR B03AA1060 (Ref. Fig. 10, Ref. Fig. 11 and Ref. Fig. 12) The dual distributor valve inflates and deflates the de-icer group. In the different icing conditions, an electronic timer controls the operation of this unit through different cycles (quick, slow ...). At the start of the de-icing cycle: – The de-energized solenoid valve A (9) is closed. – The inflation valve A (4) is closed. – The supply pressure and the spring (7) move the inflation valve A (4) to its seat. In this position, the deflation valve A (2) is open and connects the de-icer to the jet-pump suction port. The circuit A is depressurized (Ref. Fig. 10). The timer controls the energization of the solenoid valve B (10) which vents the air chamber B (11) installed above the diaphragm (12). Then, the pressure on the other face of the diaphragm opens the inflation valve B (14) and closes the deflation valve B (15). In this position, the circuit B is pressurized (Ref. Fig. 10). When the solenoid valve B (10) is de-energized, the chamber B (11) closes again and the pressure on each face of the diaphragm is balanced through the calibrated nozzle (13). The inflation valve B (14) closes while the deflation valve B (15) opens. The de-icer is depressurized quickly through the relief valve (16). The jet pump (3) depressurizes the de-icer (negative pressure). In this position, the circuit B is depressurized (Ref. Fig. 11). At the same time, the air vent chamber A (8), installed above the diaphragm A (6), is vented after the solenoid valve A (9) of the circuit “A” is energized. The pressure on the other face of the diaphragm opens the inflation valve A (4) and closes the deflation valve A (2). In this position, the circuit A is pressurized (Ref. Fig. 11). The different operating cycles of the timer give the conditions that follow: – Circuit A depressurized, circuit B pressurized (Ref. Fig. 10) (during 5 s). – Circuit A pressurized, circuit B depressurized (Ref. Fig. 11) (during 5 s). – Circuits A and B depressurized (usually when the de-icing system is not in operation) (Ref. Fig. 12). (1) Negative-pressure jet pump (3) The jet pump depressurizes the two circuits. It includes an injector and a nozzle. 30-11-76 Page 16 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 3 4 6 7 8 SUPPLY DEPRESSURE 2 A 1 9 16 10 B 15 PRESSURE 14 13 12 11 KEY CHAMBER 7 SPRING 13 NOZZLE 2 DEFLATION VALVE A 8 CHAMBER A 14 INFLATION VALVE B 3 JET PUMP 9 SOLENOID VALVE A 15 DEFLATION VALVE B 4 INFLATION VALVE A 10 SOLENOID VALVE B 16 PRESSURE RELIEF VALVE 5 N/A 11 CHAMBER B A CIRCUIT A 6 DIAGRAM A 12 DIAGRAM B B CIRCUIT B at022b01.cgm 1 Circuit A Depressurized and Circuit B Pressurized (For PNR B03AA1060) Figure 10/GRAPHIC 30-11-76-991-004-B01 30-11-76 Page 17 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 3 4 6 7 8 SUPPLY PRESSURE 2 A 1 9 16 10 B 15 DEPRESSURE 14 13 12 11 KEY CHAMBER 7 SPRING 13 NOZZLE 2 DEFLATION VALVE A 8 CHAMBER A 14 INFLATION VALVE B 3 JET PUMP 9 SOLENOID VALVE A 15 DEFLATION VALVE B 4 INFLATION VALVE A 10 SOLENOID VALVE B 16 PRESSURE RELIEF VALVE 5 N/A 11 CHAMBER B A CIRCUIT A 6 DIAGRAM A 12 DIAGRAM B B CIRCUIT B at024b01.cgm 1 Circuit A Pressurized and Circuit B Depressurized (For PNR B03AA1060) Figure 11/GRAPHIC 30-11-76-991-005-B01 30-11-76 Page 18 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 3 4 6 7 8 SUPPLY DEPRESSURE 2 A 1 9 16 10 B 15 PRESSURE 14 13 12 11 KEY CHAMBER 7 SPRING 13 NOZZLE 2 DEFLATION VALVE A 8 CHAMBER A 14 INFLATION VALVE B 3 JET PUMP 9 SOLENOID VALVE A 15 DEFLATION VALVE B 4 INFLATION VALVE A 10 SOLENOID VALVE B 16 PRESSURE RELIEF VALVE 5 N/A 11 CHAMBER B A CIRCUIT A 6 DIAGRAM A 12 DIAGRAM B B CIRCUIT B at026b01.cgm 1 Circuit A and Circuit B Depressurized (For PNR B03AA1060) Figure 12/GRAPHIC 30-11-76-991-006-B01 30-11-76 Page 19 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 20 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TESTING AND FAULT ISOLATION TASK 30-11-76-700-801-A01 1. Testing Procedure For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Instrumentation DESIGNATION QTY CHARACTERISTICS PRESSURE GAGE 1 RANGE: 2 BAR REL. (29 PSIG) ACCURACY 0,5% MILLIOHMMETER 1 RANGE: 20 MILLIOHMS ACCURACY 1% VOLTMETER 1 RANGE: 40 VDC ACCURACY 1% OHMMETER 1 RANGE: 500 OHMS ACCURACY 1% CHRONOMETER 1 STANDARD PRESSURE GAGE 2 RANGE: -1 TO 2 BAR REL. (-14.5 to 29 PSIG) DESIGNATION QTY CHARACTERISTICS AIR PRESSURE SOURCE 1 RANGE: 2 BAR REL. (29 PSIG) FLOWRATE: 2 KG/MIN (4.41 LB/MIN) STABILIZED POWER SUPPLY 1 RANGE: 0 TO 30 VDC DESIGNATION QTY CHARACTERISTICS SHUT-OFF VALVE 1 LOCAL MANUFACTURE CAPACITY 2 26 DM3 (0.92 CU.FT) ELECTRICAL CONNECTOR 2 AS PER NAS1599 (b) (c) Energy Sources Equipments 30-11-76 Page 1001 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series (d) Special Tools CODE REFERENCE QTY DESIGNATION T05 M82000403 OR EQUIVALENT 1 CONTROL BOX T06 SBE1333 1 COUPLING TOOL T07 M82000404 2 COUPLING TOOL T08 SBE1335 1 COUPLING TUBE T09 M82000189-1400 1 CABLE CIRCUIT A T10 M82000189-1401 1 CABLE CIRCUIT B T13 M65724517 1 CABLE CIRCUIT A T14 M65724518 1 CABLE CIRCUIT B T15 M65724509 1 CABLE CIRCUIT C (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-007-A01 1000 FIGURE 1001 GRAPHIC-30-11-76-991-008-A01 1000 FIGURE 1002 C. Job Set-up SUBTASK 30-11-76-210-001-A01 (1) Make sure that the test conditions are in: – Ambient temperature: 20 ± 10 °C (50 to 86 °F). D. Procedure SUBTASK 30-11-76-220-001-A01 (1) Visual Inspection (a) Make sure that the unit is complete, not damaged and that there are no scratches and no dents. (b) Make sure that the connecting ends are in good condition. (c) Make sure that the condition of electrical connector is correct. (d) Make sure that the inscriptions on the identification plate are clear. SUBTASK 30-11-76-750-001-A01 (2) Electrical Continuity Test (a) Make sure that the resistance is less than or equal to 20 milliohms: 1 Between the bonding point of the plate (01-200) and: 30-11-76 Page 1002 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series – – – – The The The The electrical connector (01-040) or (01-060) or (01-080) pressure switches (01-180) (Remove the cover (01-100)) body (01-280) Nozzle S/A (02-210). SUBTASK 30-11-76-750-002-A01 (3) Electrical Circuit Test (a) Resistance 1 Examine the resistance between pins A and B: – For the electrical connector A: R = 100 ± 10 Ω. – For the electrical connector B: R = 100 ± 10 Ω. – For the electrical connector C: R = 225 ± 22 Ω. (b) Insulation Resistance Test 1 Pressure switch and solenoid valve: a Measure the resistance between all pins linked and the ground under 50 ± 5 VDC. – Use cable circuit A (T13) for connector “A”. – Use cable circuit B (T14) for connector “B”. b 2 Make sure that the resistance is more than or equal to 100 Megohms. Re-heating a Measure the resistance between the pins A and B (connector C) with the cable circuit C (T15) linked and the ground under 500 ± 5 VDC. b Make sure that the resistance is more than or equal to 10 Megohms. 30-11-76 Page 1003 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series CONNECTOR A T09 CABLE CIRCUIT A A SOLEMOID VALVE A B C D E F + 28 Vdc PRESSURE SWITCH 0V SOLEMOID VALVE A B C D E F PRESSURE SWITCH T10 CABLE CIRCUIT B OFF CONNECTOR B ON A T15 RE-HEATING JET PUMP A B C 115 Vdc RE-HEATING PRESSURE SWITCHES CABLE CIRCUIT C 115 V 400 Hz CONNECTOR C RE-HEATING SOLENOID A AND B at027b01.cgm T05 CONTROL BOX OR EQUIVALENT Wiring Diagram (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) Figure 1001/GRAPHIC 30-11-76-991-007-A01 30-11-76 Page 1004 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series SUBTASK 30-11-76-700-001-A01 (4) Functional Test of the Pressure Switches (Ref. Fig. 1001) (Ref. Fig. 1002) – Solenoid valves A and B are energized under a 28 ± 1 VDC supply. – Initial pressure supply equal to: 0 mbar. (a) Increase the pressure (P1) The re-starting pressure of the pressure switch A and B are comprised between 1160 and 1240 mbar rel. (16.8 to 18 psig) (values for which the pilot lamp is switched off). (b) Decrease the pressure (P1) to 0 bar rel. (0 psig) The pilot lamp is switched on for a pressure of the two pressure switches A and B more than 800 mbar (11.60 psi). NOTE: Do the functional test of the pressure switches three times. SUBTASK 30-11-76-700-002-A01 (5) Functional Test (Ref. Fig. 1001) (Ref. Fig. 1002) (a) Set-up the installation. (b) Apply a pressure of 1300 + 0 / + 20 mbar rel. (18.85 to 19.14 psig). (c) Examine the outlet values in accordance with the solenoid condition (supply voltage 17 ± 1 VDC). TEST PRESSURE SUPPLY TIME SOLENOID VALVE OUTLET PRESSURE MEASUREMENT AFTER THE PRESSURE SUPPLY TIME A B A CIRCUIT PRESSURE B CIRCUIT PRESSURE ≤ 30 S NOT ENERGIZED NOT ENERGIZED NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) ≤5S ENERGIZED NOT ENERGIZED P1 - PA ≤ 10 MBAR (0.145 PSI) NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) ≤ 30 S NOT ENERGIZED NOT ENERGIZED NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) ≤5S NOT ENERGIZED ENERGIZED NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) P1 - PB ≤ 10 MBAR (0.145 PSI) NOTE: Do the functional test three times. 30-11-76 Page 1005 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series E. Close-up Not applicable 30-11-76 Page 1006 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series P1 0 - 2 bar rel. (0 to 29 psig) 0 ID. Dia. ≥ 16 mm (0.63 in) T05 SHUT-OFF VALVE CONTROL BOX OR EQUIVALENT AIR SUPPLY 0 - 2 bar rel. (0 to 29 psig) DUAL DISTRIBUTOR VALVE T08 COUPLING TUBE PA - 1 / + 2 bar rel. (- 14.5 to 29 psig) T07 T06 COUPLING TOOL "A" WAY COUPLING PB TOOL - 1 / + 2 bar rel. (- 14.5 to 29 psig) "B" WAY 0 0 CAPACITY 26 dm³ (0.92 cu.ft) at029b01.cgm CAPACITY 26 dm³ (0.92 cu.ft) Functional Test (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) Figure 1002/GRAPHIC 30-11-76-991-008-A01 30-11-76 Page 1007 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-700-801-B01 2. Testing Procedure For PNR B03AA1060, B03AA1060 Amdt A and B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Instrumentation DESIGNATION QTY CHARACTERISTICS PRESSURE GAGE 1 RANGE: 2 BAR REL. (29 PSIG) ACCURACY 0,5% MILLIOHMMETER 1 RANGE: 20 MILLIOHMS ACCURACY 1% VOLTMETER 1 RANGE: 40 VDC ACCURACY 1% OHMMETER 1 RANGE: 500 OHMS ACCURACY 1% CHRONOMETER 1 STANDARD PRESSURE GAGE 2 RANGE: -1 TO 2 BAR REL. (-14.5 to 29 PSIG) ACCURACY 0,5% DESIGNATION QTY CHARACTERISTICS AIR PRESSURE SOURCE 1 RANGE: 2 BAR REL. (29 PSIG) FLOWRATE: 2 KG/MIN (4.41 LB/MIN) STABILIZED POWER SUPPLY 1 RANGE: 0 TO 30 VDC DESIGNATION QTY CHARACTERISTICS SHUT-OFF VALVE 1 LOCAL MANUFACTURE CAPACITY 2 26 DM3 (0.92 CU.FT) ELECTRICAL CONNECTOR 2 AS PER NAS1599 (b) (c) Energy Sources Equipments 30-11-76 Page 1008 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series (d) Special Tools CODE REFERENCE QTY DESIGNATION T05 M82000403 OR EQUIVALENT 1 CONTROL BOX T06 SBE1333 1 COUPLING TOOL T07 M82000404 2 COUPLING TOOL T08 SBE1335 1 COUPLING TUBE T11 M82000189-1402 1 CABLE CIRCUIT A T12 M82000189-1403 1 CABLE CIRCUIT B (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-007-B01 1000 FIGURE 1003 GRAPHIC-30-11-76-991-008-B01 1000 FIGURE 1004 C. Job Set-up SUBTASK 30-11-76-210-001-B01 (1) Make sure that the test conditions are in: – Ambient temperature: 20 ± 10 °C (50 to 86 °F). D. Procedure SUBTASK 30-11-76-220-001-B01 (1) Visual Inspection (a) Make sure that the unit is complete, not damaged and that there are no scratches and no dents. (b) Make sure that the connecting ends are in good condition. (c) Make sure that the condition of electrical connector is correct. (d) Make sure that the inscriptions on the identification plate are clear. SUBTASK 30-11-76-750-001-B01 (2) Electrical Continuity Test (a) Make sure that the resistance is less than or equal to 20 milliohms: 1 Between the bonding point of the plate (01A-200) and: 30-11-76 Page 1009 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series – The connectors (01A-060) or (01A-080) – The bodies (01A-280) of the solenoïd – The Nozzle S/A (02A-210) SUBTASK 30-11-76-750-002-B01 (3) Electrical Circuit Test (a) Resistance 1 Examine the resistance between pins 1 and 2: – For the electrical connector A: R = 100 ± 10 Ω. – For the electrical connector B: R = 100 ± 10 Ω. (b) Insulation Resistance Test of the circuits “A” and “B” NOTE: Use cable (T16) for the circuit “A” and cable (T17) for the circuit “B”. 1 Solenoid valve: a Measure between all pins linked and the ground under 50 VDC. b Make sure that the resistance is more than or equal to 100 Megohms. 30-11-76 Page 1010 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series CONNECTOR A T11 CABLE CIRCUIT A A SOLEMOID VALVE 1 2 3 4 5 + 28 Vdc 0V OFF ON A T12 115 V 400 Hz CABLE CIRCUIT B SOLEMOID VALVE 1 2 3 4 5 CONNECTOR B at028a01.cgm T05 CONTROL BOX OR EQUIVALENT Wiring Diagram (For Types B03AA1060, B03AA1060 Amdt A and B) Figure 1003/GRAPHIC 30-11-76-991-007-B01 30-11-76 Page 1011 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series SUBTASK 30-11-76-700-002-B01 (4) Functional Test (Ref. Fig. 1003) (Ref. Fig. 1004) (a) Set-up the installation. (b) Apply a pressure of 1400 ± 10 mbar rel. (20.16 to 20.45 psig). (c) Examine the outlet values in accordance with the solenoid condition (supply voltage 17 ± 1 VDC). TEST PRESSURE SUPPLY TIME SOLENOID VALVE OUTLET PRESSURE MEASUREMENT AFTER THE PRESSURE SUPPLY TIME A B A CIRCUIT PRESSURE B CIRCUIT PRESSURE 30 S NOT ENERGIZED NOT ENERGIZED NEGATIVE PRESSURE ≤ -70 MBAR REL (1.02 PSIG) NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) 5S ENERGIZED NOT ENERGIZED POSITIVE PRESSURE 1400 ± 10 MBAR (20.16 TO 20.45 PSI) NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) 30 S NOT ENERGIZED NOT ENERGIZED NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) 5S NOT ENERGIZED ENERGIZED NEGATIVE PRESSURE ≤ -70 MBAR REL. (1.02 PSIG) POSITIVE PRESSURE 1400 ± 10 MBAR (20.16 TO 20.45 20.45 PSI) NOTE: Do the functional test three times. E. Close-up Not applicable 30-11-76 Page 1012 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series P1 0 - 2 bar rel. (0 to 29 psig) 0 ID. Dia. ≥ 16 mm (0.63 in) T05 SHUT-OFF VALVE CONTROL BOX OR EQUIVALENT AIR SUPPLY 0 - 2 bar rel. (0 to 29 psig) DUAL DISTRIBUTOR VALVE T08 COUPLING TUBE PA - 1 / + 2 bar rel. (- 14.5 to 29 psig) T07 T06 COUPLING TOOL "A" WAY COUPLING PB TOOL - 1 / + 2 bar rel. (- 14.5 to 29 psig) "B" WAY 0 0 CAPACITY 26 dm³ (0.92 cu.ft) at030b01.cgm CAPACITY 26 dm³ (0.92 cu.ft) Functional Test (For Types B03AA1060, B03AA1060 Amdt A and B) Figure 1004/GRAPHIC 30-11-76-991-008-B01 30-11-76 Page 1013 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-810-801-A01 3. Fault Isolation For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Referenced Information REFERENCE PAGE BLOCK DESIGNATION SUBTASK-30-11-76-220-001-A01 1000 VISUAL INSPECTION SUBTASK-30-11-76-700-001-A01 1000 FUNCTIONAL TEST OF THE PRESSURE SWITCHES SUBTASK-30-11-76-700-002-A01 1000 FUNCTIONAL TEST SUBTASK-30-11-76-750-001-A01 1000 INSULATION TEST SUBTASK-30-11-76-750-002-A01 1000 ELECTRICAL CONTINUITY TEST SUBTASK-30-11-76-020-001-A01 3000 REMOVAL OF THE CONNECTORS (01-040), (01-060) AND (01-080) SUBTASK-30-11-76-020-002-A01 3000 REMOVAL OF THE PRESSURE SWITCHES (01-180) SUBTASK-30-11-76-020-004-A01 3000 REMOVAL OF THE PRESSURE RELIEF VALVE (01-270) AND THE SOLENOID VALVES SUBTASK-30-11-76-020-006-A01 3000 REMOVAL OF THE DUAL VALVES TASK-30-11-76-300-802-A01 6000 REPAIR No. 2: ELECTRICAL BONDING SUBTASK-30-11-76-420-005-A01 7000 INSTALLATION OF THE PRESSURE SWITCHES SUBTASK-30-11-76-420-006-A01 7000 INSTALLATION OF THE HEATING RESISTORS (1P) AND (2P) (01-140) SUBTASK-30-11-76-420-008-A01 7000 INSTALLATION OF THE CONNECTORS (01-060) AND (01-080) SUBTASK-30-11-76-420-009-A01 7000 INSTALLATION OF THE PRESSURE RELIEF VALVE SUBTASK-30-11-76-440-001-A01 7000 ASSEMBLY OF THE SOLENOID VALVE SUBTASK-30-11-76-440-002-A01 7000 ASSEMBLY OF THE DUAL VALVE C. Job Set-up Not applicable D. Fault Isolation Procedure 30-11-76 Page 1014 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series DEFECT POSSIBLE CAUSE CORRECTION 1. Visual inspection (Ref. Para. 1.D.(1) SUBTASK 30-11-76-220-001-A01) Visual defect There is impact damage, crack. Replace the defective parts. 2. Electrical Continuity Test (Ref. Para. 1.D.(2) SUBTASK 30-11-76-750-001-A01) Electrical continuity R > 20 milliohms Corrosion at bonding points. Apply bonding steps (Ref. REPAIR No. 2 TASK 30-11-76-300-802-A01). 3. Electrical Circuit Test (Ref. Para. 1.D.(3) SUBTASK 30-11-76-750-002-A01) Resistance > 110 Ω or < 90 Ω for connectors A and B The solenoid valve is defective. Examine the solenoid valve. Replace the solenoid valve (Ref. SUBTASK 30-11-76020-004-A01), (Ref. SUBTASK 30-11-76-440-001-A01). Resistance > 247 Ω for the connector C The heating resistance(s) is(are) defective. Examine the heating resistances. Replace the heating resistances (Ref. SUBTASK 30-11-76020-002-A01), (Ref. SUBTASK 30-11-76-420-006-A01). Insulation resistance (solenoid valve and pressure switch) < 100 Megohms Insulation resistance (Re-heating) < 10 Megohms – Re-heating wiring – Solenoid reheating – Resistor heating – Pins are incorrectly insulated. – The solenoid valve is defective. – The pressure switch is defective. – Replace the connector (Ref. SUBTASK 30-11-76-020001-A01), (Ref. SUBTASK 30-11-76-420-008-A01). – Replace the solenoid valve (Ref. SUBTASK 30-11-76-020004-A01), (Ref. SUBTASK 30-11-76-440-001-A01). – Replace the pressure switch (Ref. SUBTASK 30-11-76-020002-A01), (Ref. SUBTASK 30-11-76-420-005-A01). – – – – – – Replace the connector, (Ref. SUBTASK 30-11-76-020001-A01), (Ref. SUBTASK 30-11-76-420-008-A01). – Replace the re-heating, (Ref. SUBTASK 30-11-76-020001-A01), (Ref. SUBTASK 30-11-76-700-004-A01). Pins are incorrectly insulated. Re-heating is defective. Re-heating wiring Solenoïd Re-heating Resistor heating 4. Functional Test of the Pressure Switches (Ref. Para. 1.D.(4) SUBTASK 30-11-76-700-001-A01) 30-11-76 Page 1015 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series DEFECT Values out of tolerances POSSIBLE CAUSE CORRECTION The pressure switches are defective. Replace the pressure switches (Ref. SUBTASK 30-11-76020-002-A01), (Ref. SUBTASK 30-11-76-420-005-A01). 5. Functional Test (Ref. Para 1.D.(5) SUBTASK 30-11-76-700-002-A01) No overpressure and no depressurization No overpressure No depressurization – The diaphragm (01-360) of the double valve is defective. – The equipped diaphragm (02-180) is defective. – The pressure relief valve (01-270) is defective. – The body (02-340) is defective. – Replace the diaphragm (01-360) (Ref. SUBTASK 30-11-76-020004-A01), (Ref. SUBTASK 30-11-76-440-001-A01). – Replace the diaphragm (02-180) (Ref. SUBTASK 30-11-76-020006-A01), (Ref. SUBTASK 30-11-76-440-002-A01). – Replace the pressure relief valve (01-270) (Ref. SUBTASK 30-1176-020-004-A01), (Ref. SUBTASK 30-11-76-420-009-A01). There is tightness defect of the preformed packings (01-190). Replace the preformed packings (01-190) (Ref. SUBTASK 30-1176-020-002-A01), (Ref. SUBTASK 30-11-76-420-005-A01). There is jamming of the axle (02-200) in the guide of the double valve. Replace the axle (02-200) (Ref. SUBTASK 30-11-76020-006-A01), (Ref. SUBTASK 30-11-76-440-002-A01). There is tightness defect of the pressure relief valves on the double valve. Replace the valves (02-170) or (02-110) (Ref. SUBTASK 30-1176-020-006-A01), (Ref. SUBTASK 30-11-76-440-002-A01). There is a tightness defect of the core in the solenoid valve. Replace the solenoid valve (Ref. SUBTASK 30-11-76020-004-A01), (Ref. SUBTASK 30-11-76-440-001-A01). There is jamming of the core in the solenoid valve. Replace the solenoid valve (Ref. SUBTASK 30-11-76020-004-A01), (Ref. SUBTASK 30-11-76-440-001-A01). There is tightness defect of the depressurization valves on the double valve. Replace the valves (02-110) (Ref. SUBTASK 30-11-76020-006-A01), (Ref. SUBTASK 30-11-76-440-002-A01). There is leakage defect of the pressure relief valve. Replace the valves (02-110) or the axle (02-200) (Ref. SUBTASK 30-1176-020-006-A01), (Ref. SUBTASK 30-11-76-440-002-A01). 30-11-76 Page 1016 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series E. Close-up Not applicable 30-11-76 Page 1017 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-810-801-B01 4. Fault Isolation For PNR B03AA1060, B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Referenced Information REFERENCE PAGE BLOCK DESIGNATION SUBTASK-30-11-76-220-001-B01 1000 VISUAL INSPECTION SUBTASK-30-11-76-700-001-B01 1000 FUNCTIONAL TEST OF THE PRESSURE SWITCHES SUBTASK-30-11-76-700-002-B01 1000 FUNCTIONAL TEST SUBTASK-30-11-76-750-001-B01 1000 INSULATION TEST SUBTASK-30-11-76-750-002-B01 1000 ELECTRICAL CONTINUITY TEST SUBTASK-30-11-76-020-001-B01 3000 REMOVAL OF THE CONNECTORS (01-040), (01-060) AND (01-080) SUBTASK-30-11-76-020-002-B01 3000 REMOVAL OF THE PRESSURE SWITCHES (01-180) SUBTASK-30-11-76-020-004-B01 3000 REMOVAL OF THE PRESSURE RELIEF VALVE (01-270) AND THE SOLENOID VALVES SUBTASK-30-11-76-020-006-B01 3000 REMOVAL OF THE DUAL VALVES TASK-30-11-76-300-802-B01 6000 REPAIR No. 2: ELECTRICAL BONDING SUBTASK-30-11-76-420-005-B01 7000 INSTALLATION OF THE PRESSURE SWITCHES SUBTASK-30-11-76-420-008-B01 7000 INSTALLATION OF THE CONNECTORS (01-060) AND (01-080) SUBTASK-30-11-76-420-009-B01 7000 INSTALLATION OF THE PRESSURE RELIEF VALVE SUBTASK-30-11-76-440-001-B01 7000 ASSEMBLY OF THE SOLENOID VALVE SUBTASK-30-11-76-440-002-B01 7000 ASSEMBLY OF THE DUAL VALVES GRAPHIC-30-11-76-991-001-B-01 1 FIGURE 2 C. Job Set-up Not applicable 30-11-76 Page 1018 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series D. Fault Isolation Procedure DEFECT POSSIBLE CAUSE CORRECTION 1. Visual inspection (Ref. Para. 2.D.(1) SUBTASK 30-11-76-220-001-B01) Visual defect There is traces of impact or cracks. Remove the defective parts. The lockwire is broken or not correctly installed. Safety the lockwire (Ref. Fig. 2 Sheet 1/2). 2. Electrical Continuity Test (Ref. Para. 2.D.(2) SUBTASK 30-11-76-750-001-B01) Electrical continuity R > 20 milliohms Corrosion at bonding points. Apply bonding steps (Ref. REPAIR No. 2 TASK 30-11-76-300-802-B01). 3. Electrical Circuit Test (Ref. Para. 2.D.(3) SUBTASK 30-11-76-750-002-B01) Resistance > 110 Ω for connectors A and B Insulation resistance < 100 Megohms The solenoid valve is defective. Examine the solenoid valve . Replace the solenoid valve (Ref. SUBTASK 30-11-76020-004-B01), (Ref. SUBTASK 30-11-76-440-001-B01). The connectors are defective. Replace the connectors (Ref. SUBTASK 30-11-76-020-001-B01), (Ref. SUBTASK 30-11-76-420007-B01). – Pins are incorrectly insulated. – The solenoid valve is defective. – Replace the connector (Ref. SUBTASK 30-11-76-020001-B01), (Ref. SUBTASK 30-11-76-420-007-B01). – Replace the solenoid valve (Ref. SUBTASK 30-11-76-020004-B01), (Ref. SUBTASK 30-11-76-440-001-B01). 4. Functional Test (Ref. Para 2.D.(4) SUBTASK 30-11-76-700-002-B01) 30-11-76 Page 1019 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series DEFECT No overpressure and no depressurization No overpressure No depressurization E. POSSIBLE CAUSE CORRECTION – The diaphragm (01A-360) of the double valve is defective. – The equipped diaphragm (02A-180) is defective. – The pressure relief valve (01-270) is defective. – The body (02-340) is defective. – Replace the diaphragm (01A-360) (Ref. SUBTASK 30-11-76-020004-B01), (Ref. SUBTASK 30-11-76-440-001-B01). – Replace the diaphragm (02A-180) (Ref. SUBTASK 30-11-76-020006-B01), (Ref. SUBTASK 30-11-76-440-002-B01). – Replace the pressure relief valve (01-270) (Ref. SUBTASK 30-1176-020-004-A01), (Ref. SUBTASK 30-11-76-420-009-A01). There is tightness defect of the preformed packings (01A-190). Replace the preformed packings (01A-190) (Ref. SUBTASK 30-1176-020-003-B01), (Ref. SUBTASK 30-11-76-420-005-B01). There is jamming of the axle (02A-200) in the guide of the double valve. Replace the axle (02A-200) (Ref. SUBTASK 30-11-76020-006-B01), (Ref. SUBTASK 30-11-76-440-002-B01). There is tightness defect of the pressure relief valves on the double valve. Replace the valves (02A-170) or (02A-110) (Ref. SUBTASK 30-1176-020-006-B01), (Ref. SUBTASK 30-11-76-440-002-B01). There is a tightness defect of the core in the solenoid valve. Replace the solenoid valve (Ref. SUBTASK 30-11-76020-004-B01), (Ref. SUBTASK 30-11-76-440-001-B01). There is jamming of the core in the solenoid valve. Replace the solenoid valve (Ref. SUBTASK 30-11-76020-004-B01), (Ref. SUBTASK 30-11-76-440-001-B01). There is tightness defect of the depressurization valves on the double valve. Replace the valves (02A-110) (Ref. SUBTASK 30-11-76020-006-B01), (Ref. SUBTASK 30-11-76-440-002-B01). There is leakage defect of the pressure relief valve. Replace the valves (02A-110) or the axle (02A-200) , (Ref. SUBTASK 30-1176-020-006-B01), (Ref. SUBTASK 30-11-76-440-002-B01). Close-up Not applicable 30-11-76 Page 1020 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series DISASSEMBLY TASK 30-11-76-040-801-A01 1. Disassembly of the Dual Distributor Valve (01-001) (Ref. IPL Fig. 01) For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Special Tools CODE REFERENCE QTY DESIGNATION T01 M65724395 1 SUPPORT T04 M65725780 1 WRENCH (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-024-A01 10000 IPL FIGURE 01 C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-020-001-A01 (1) Removal of the Connectors (01-040), (01-060), (01-080) and the Cover (01-010) (a) Install the unit on the support (T01). (b) Cut the lockwire (02-330). (c) Remove the screws (01-020) and (01-030). (d) Remove the cover (01-010). (e) Remove the clamps (01-415). (f) Remove the screws (01-050), (01-070) and (01-090). (g) Disengage the connectors (01-040), (01-060) and (01-080) from the cover (02-040). (h) Remove the heat sleeve (01-410) from all the wires of the connectors (01-040), (01-060) and (01-080). (i) Unsolder all the wires from the connectors (01-040), (01-060) and (01-080). 30-11-76 Page 3001 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (j) Disconnect the six white wires (01-390) from the junction module (01-380). (k) Remove the connectors (01-040). (l) Remove the connectors (01-060) and (01-080). SUBTASK 30-11-76-020-002-A01 (2) Removal of the Pressure Switches (01-180) (a) Remove the screws (01-110) and the cover (01-100). (b) Remove the screw (01-130) and the plate (01-120). (c) Remove the two heating resistors (01-140). (d) Disconnect heating resistor wires from the junction module (01-380). (e) Remove the two nuts (01-160) and the two screws (01-170). (f) Remove the body (01-150). (g) Remove the two pressure switches (01-180) with the wrench (T04). (h) Remove the preformed packings (01-190). SUBTASK 30-11-76-020-003-a01 (3) Removal of the Plate (01-200) (a) Remove the screws (01-210) (cross screwdriver). (b) Remove the screw (01-230) and the nut (01-220). (c) Remove the plate (01-200) SUBTASK 30-11-76-020-004-A01 (4) Removal of the Pressure Relief Valve (01-270) and the Solenoid Valves (a) (b) Removal of the pressure relief valve (01-270) 1 Remove the screws (01-250) and the cover (01-240). 2 Remove the spring (01-260). 3 Remove the pressure relief valve (01-270). Removal of the solenoid valves 1 Remove the two screws (01-290) and the body (01-280). 2 Remove the diaphragm (01-360). 3 Remove the core (01-350) and the spring (01-320). 4 Remove the shims (01-330) and (01-340). 5 If necessary, remove the knurled nails (01-300). 30-11-76 Page 3002 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 6 Remove the coil (01-370). 7 Remove the shim (01-310). 8 Remove the shrinkable heat sleeve (01-410). NOTE: Do the same procedure for the other solenoid valve. 9 E. Remove the bonding plate (01-430). Close-up Not applicable 30-11-76 Page 3003 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-040-802-A01 2. Disassembly of the Equipped Body S/A (02-001) (Ref. IPL Fig. 02) For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-025-A01 10000 IPL FIGURE 02 TASK-30-11-76-040-801-A01 3000 DISASSEMBLY OF THE DUAL DISTRIBUTOR VALVE (01-001) (FOR TYPES B03AA1040, B03AA1040 AMDT A, B, C, D, E) C. Job Set-up SUBTASK 30-11-76-050-001-A01 (1) Preliminary Operation (a) D. Disassemble the dual distributor valve (01-001) (Ref. TASK 30-11-76-040-801-A01). Procedure SUBTASK 30-11-76-020-005-A01 (1) Removal of the Nozzle S/A (02-210) (a) Remove the three screws (02-220B). (b) Remove the preformed packings (02-270), (02-280) (02-290) and (02-300). (c) Remove the sealing material (M50B) on the heating resistors (02-310). (d) Disconnect heating resistor wires from the junction module (01-380). (e) Remove the heating resistors (02-310) and the springs (02-320). (f) Remove the nozzle (02-230) from the body (02-260). (g) Remove the injector (02-240). SUBTASK 30-11-76-020-005-B01 (2) Removal of the Nozzle S/A (02-210B) (a) Remove the preformed packings (02-300) and (02-290). 30-11-76 Page 3004 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (b) Remove the screws (02-220) and (02-225). (c) Remove the sealing material (M50B) on the heating resistors (02-310). (d) Disconnect heating resistor wires from the junction module (01-380). (e) Remove the heating resistors (02-310). (f) Remove the nozzle (02-230B) from the body (02-260). (g) Remove the injector (02-240B) and the preformed packing (02-250) from the body (02-260). SUBTASK 30-11-76-020-006-A01 (3) Removal of the Dual Valves (a) Remove the screw (02-020) and the plate (02-010). (b) Remove the guide (02-070) and the preformed packing (02-080). (c) If necessary, remove the silent block (02-030). (d) Remove the screws (02-050) and the cover (02-040). (e) Remove the springs (02-060). (f) Remove the nut (02-100), the Lower Flange S/A (02-090) and the valve (02-110). (g) Remove the washer (02-120) and the upper flange (02-130). (h) Remove the spacer (02-140) and the washer (02-150). (i) Remove the equipped valve (02-170) and the preformed packing (02-160). (j) Remove the nut (02-190) and the equipped diaphragm (02-180). (k) Remove the axle (02-200). NOTE: Do the same procedure for the other dual valve. (l) E. Remove the protective plugs (02-350) and (02-360). Close-up Not applicable 30-11-76 Page 3005 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-040-801-B01 3. Disassembly of the Dual Distributor Valve (01A-001) (Ref. IPL Fig. 01A) For PNR B03AA1060, B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Special Tools CODE REFERENCE QTY DESIGNATION T01 M65724395 1 SUPPORT (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-024-B01 10000 IPL FIGURE 1A C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-020-001-B01 (1) Removal of the Connectors (01A-060) and (01A-080) and the Cover (01A-010) (a) Install the unit on the support (T01). (b) Cut the lockwire (02A-330). (c) Remove the screws (01A-020) and (01A-030). (d) Remove the cover (01A-010). (e) Remove the clamps (01A-415). (f) Remove the screws (01A-050), (01A-070) and (01A-090). (g) Disengage the connectors (01A-060), (01A-080) from the cover (02A-040).. (h) Remove the heat sleeve (01A-410) from all the wires of the connectors (01A-060) and (01A-080). (i) Remove the plate (01A-040). (j) Unsolder all the wires from the connectors (01A-060) and (01A-080). 30-11-76 Page 3006 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (k) Remove the connectors (01A-060) and (01A-080). (l) Remove the spacer (01A-095). 30-11-76 Page 3007 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series SUBTASK 30-11-76-020-003-B01 (2) Removal of the Threaded Plugs (01A-170) and the Plate (01A-200) (a) (b) Removal of the threaded plugs (01A-170) 1 Remove the threaded plugs (01A-170). 2 Remove the preformed packings (01A-190). Removal of the Plate (01A-200) 1 Remove the screws (01A-210) (cross screwdriver). 2 Remove the screw (01A-230) and the nut (01A-220). SUBTASK 30-11-76-020-004-B01 (3) Removal of the Pressure Relief Valve (01A-270) and the Solenoid Valves (a) (b) Removal of the pressure relief valve (01A-270) 1 Remove the screws (01A-250) and the cover (01A-240). 2 Remove the spring (01A-260). 3 Remove the pressure relief valve (01A-270). Removal of the Solenoid Valves 1 Remove the two screws (01A-290) and the body (01A-280). 2 Remove the diaphragm (01A-360). 3 Remove the core (01A-350) and the spring (01A-320). 4 If necessary, remove the knurled nail (01A-300). 5 Remove the shims (01A-330) and (01A-340). 6 Remove the coil (01A-370) and the shims (01A-310). NOTE: Do the same procedure for the other solenoid valve. E. Close-up Not applicable 30-11-76 Page 3008 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-040-802-B01 4. Disassembly of the Equipped Body S/A (02A-001) (Ref. IPL Fig. 02A) For PNR B03AA1060, B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-025-B01 10000 IPL FIGURE 2A TASK-30-11-76-040-801-B01 3000 DISASSEMBLY OF THE DUAL DISTRIBUTOR VALVE (01A-001) (FOR TYPES B03AA1060, B03AA1060 AMDT A, B) C. Job Set-up SUBTASK 30-11-76-050-001-B01 (1) Preliminary Operation (a) D. Disassemble the dual distributor valve (01A-001) (Ref. TASK 30-11-76-040-801-B01). Procedure SUBTASK 30-11-76-020-005-C01 (1) Removal of the Nozzle S/A (02A-210) (a) Remove the three screws (02A-220B). (b) Remove the nozzle (02A-230). (c) Remove the injector (02A-240). (d) Remove the preformed packings (02A-270), (02A-280), (02A-290) and (02A-300). SUBTASK 30-11-76-020-005-D01 (2) Removal of the Nozzle S/A (02A-210B) (a) Remove the screws (02A-220) and (02A-225). (b) Remove the nozzle (02A-230B) from the body (02A-260). (c) Remove the injector (02A-240B) and the preformed packing (02A-250) from the body (02A-260). 30-11-76 Page 3009 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (d) Remove the preformed packings (02A-300) and (02A-290). SUBTASK 30-11-76-020-006-B01 (3) Removal of the Dual Valves (a) Remove the screw (02A-020) and the plate (02A-010). (b) Remove the guide (02A-070) and the preformed packing (02A-080). (c) If necessary, remove the silent block (02A-030). (d) Remove the screws (02A-050) and the cover (02A-040). (e) Remove the springs (02A-060). (f) Remove the nut (02A-100), the Lower Flange S/A (02A-090) and the valve (02A-110). (g) Remove the washer (02A-120) and the upper flange (02A-130). (h) Remove the spacer (02A-140) and the washer (02A-150). (i) Remove the equipped valve (02A-170) and the preformed packing (02A-160). (j) Remove the nut (02A-190) and the equipped diaphragm (02A-180). (k) Remove the axle (02A-200). (l) Remove the protective plugs (02A-350) and (02A-360). NOTE: Do the same procedure for the other dual valve. E. Close-up Not applicable 30-11-76 Page 3010 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series CLEANING TASK 30-11-76-100-801-A01 1. External Cleaning of a Unit A. Reason for the Job WARNING: – – – – CAUTION: DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME. – CAREFULLY OBEY THE CLEANING PROCEDURES, OR REPLACE THEM WITH A PROCEDURE WHICH IS SPECIFIED BY THE MANUFACTURER IF YOU USE EQUIVALENTS. – AFTER YOU COMPLETE THE PROCEDURE, YOU MUST PUT PROTECTIVE CAPS OR APPLICABLE PACKAGING MATERIAL ON THE PARTS. Self-explanatory B. Job Set-up Information (1) Consumable Materials CODE REFERENCE DESIGNATION M09A LOCAL PURCHASE DENATURED METHANOL NOTE: Refer to the Consumable Materials Table (Ref. TASK 30-11-76-941-801-A01) for all the data in the list. C. Job Set-up SUBTASK 30-11-76-620-001-A01 (1) Preparation of the Unit (a) D. Put all the protective caps on the units. Procedure SUBTASK 30-11-76-160-001-A01 (1) External Cleaning of the Unit WARNING: DO NOT USE DIPPING OR SPRAYING PROCEDURES FOR FULL UNITS. DIPPING OR SPRAYING PROCEDURES ARE ONLY FOR ISOLATED PARTS. E. (a) Clean the unit with a lint-free cloth, which you make moist with cleaning material (M09A). As an alternative, use a soft brush. (b) Dry with low-pressure compressed air, or with a lint-free cloth. Close-up Not applicable 30-11-76 Page 4001 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-100-802-A01 2. Cleaning of a Sub-Assembly A. Reason for the Job WARNING: – – – – CAUTION: DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME. – CAREFULLY OBEY THE CLEANING PROCEDURES, OR REPLACE THEM WITH A PROCEDURE WHICH IS SPECIFIED BY THE MANUFACTURER IF YOU USE EQUIVALENTS. – AFTER YOU COMPLETE THE PROCEDURE, YOU MUST PUT PROTECTIVE CAPS OR APPLICABLE PACKAGING MATERIAL ON THE PARTS. Self Explanatory B. Job Set-up Information (1) Referenced Information REFERENCE PAGE BLOCK DESIGNATION TASK-30-11-76-100-804-A01 4000 CLEANING PROCEDURE TABLE C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-160-002-A01 (1) Cleaning of the Sub-Assembly (a) E. Refer to the Cleaning Procedure Table (Ref. TASK 30-11-76-100-804-A01): do the procedure which is given for the most easily damaged part. Close-up Not applicable 30-11-76 Page 4002 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-100-803-A01 3. Cleaning of Component Parts A. Reason for the Job WARNING: – – – – CAUTION: DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME. – CAREFULLY OBEY THE CLEANING PROCEDURES, OR REPLACE THEM WITH A PROCEDURE WHICH IS SPECIFIED BY THE MANUFACTURER IF YOU USE EQUIVALENTS. – AFTER YOU COMPLETE THE PROCEDURE, YOU MUST PUT PROTECTIVE CAPS OR APPLICABLE PACKAGING MATERIAL ON THE PARTS. Self-explanatory B. Job Set-up Information (1) Referenced Information REFERENCE PAGE BLOCK DESIGNATION TASK-30-11-76-100-804-A01 4000 CLEANING PROCEDURE TABLE C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-160-003-A01 (1) Cleaning of the Component Parts E. (a) Clean each part to remove oil, grease and dirt. (b) Make sure that the mating areas are fully free from packing material or sealing compound. (c) Use the applicable cleaning procedure (Ref. TASK 30-11-76-100-804-A01). Close-up Not applicable 30-11-76 Page 4003 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-100-804-A01 4. Cleaning Procedure A. Cleaning ProcedureTable CLEANING PROCEDURE TYPE OF PART THAT YOU WILL CLEAN 1 2 3 O O X FORGED LIGHT ALLOY WITH ANODIC-CHROMIC PROTECTION X X CAST LIGHT ALLOY WITH ANODIC-CHROMIC PROTECTION X X NITRIDE TITANIUM PLATING X X CHEMICAL NICKEL PLATING X X X X STAINLESS STEEL X TITANIUM (*) PLASTIC 4 X X COMPOSITE MATERIALS (POLYESTER) X X ELECTRICAL AND ELECTRONIC COMPONENTS TEFLON PLATING (**) RUBBER (***) CLEANING PROCEDURES 1: Heavy alkaline cleaning: (Ref. TASK 30-11-76-100-805-A01) 2: Cleaning of the parts with solvents (non chlorinated), with a dipping or spraying procedure: (Ref. TASK 30-11-76-100-806-A01) 3: Light alkaline cleaning: (Ref. TASK 30-11-76-100-807-A01) 4: Cleaning of the parts with an alcohol-based cleaning agent: (Ref. TASK 30-11-76-100-808-A01) O O: DO THE TWO STEPS, ONE AFTER THE OTHER (*): DO NOT USE CHLORINATED SOLVENT (**): DO NOT USE CLEANING MATERIAL. USE A DRY LINT-FREE CLOTH (***): DO NOT USE CLEANING MATERIAL. CLEAN WITH LOW-PRESSURE COMPRESSED AIR 30-11-76 Page 4004 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-100-805-A01 5. Procedure 1: Heavy Alkaline Cleaning A. Reason for the Job WARNING: – – – – CAUTION: DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME. – USE ALL PRECAUTIONS FOR THE PROTECTION OF YOUR EYES AND YOUR SKIN WHEN YOU USE THE CLEANING MATERIAL IN THIS PROCEDURE. THIS CLEANING MATERIAL CONTAINS SODIUM HYDROXIDE, WHICH IS HIGHLY DANGEROUS. Self-explanatory B. Job Set-up Information WARNING: DO NOT USE MANUAL CLEANING PROCEDURES WITH THE MATERIALS SPECIFIED IN THIS PROCEDURE. THIS PROCEDURE IS ONLY APPLICABLE TO INDUSTRIAL EQUIPMENT AND PROCEDURES (AUTOMATIC CLEANING MACHINE). CAUTION: C. DO NOT USE THIS MATERIAL FOR LIGHT ALLOYS. THE MATERIAL SPECIFIED BELOW CONTAINS SODIUM HYDROXIDE: IT CAUSES THE CORROSION OF ALUMINUM-BASED ALLOYS. (1) Use materials which agree with specification MIL-TT-C-490 MV. (2) Example: - Cleaning material (M48A). Job Set-up SUBTASK 30-11-76-880-001-A01 (1) Material Preparation (a) For the dilution proportions, refer to the manufacturer’s instructions. Example: - Cleaning material (M48A). Dilution of the Cleaning material (M48A) with 5% of water (for grease, baked grease, and scale particles). D. Procedure WARNING: USE ALL PRECAUTIONS AS GIVEN IN THE WARNING NOTES AT THE TOP OF PARA. A. SUBTASK 30-11-76-130-001-A01 (1) Cleaning (a) To clean the part, put it momentarily in a warm bath of cleaning material, at a temperature of 70 °C to 80 °C (158 °F to 176 °F). An ultrasonic device must mix the bath. (b) Flush the part with water. 30-11-76 Page 4005 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series CAUTION: DO NOT DRY SUB-ASSEMBLIES WHICH CONTAIN PRESS-FITTED PARTS IN THE TEMPERATURE RANGE GIVEN BELOW. THIS CAN CAUSE DISTORTION OR INTERNAL CORROSION. USE THE CORRECT DRYING TEMPERATURE. (c) E. Dry the part in hot air, at between 100 °C and 110 °C (212 °F to 230 °F). Close-up Not applicable 30-11-76 Page 4006 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-100-806-A01 6. Procedure 2: Cleaning with Solvents by the Dipping or the Spraying Procedure A. Reason for the Job WARNING: USE SOLVENTS WHICH HAVE A FLASH POINT OF MORE THAN 50 °C TO 55 °C (122 °F TO 131 °F) IN SPECIFIED STABLE CONDITIONS. WARNING: DO NOT USE ANY CHLORINATED SOLVENT. CHLORINATED SOLVENTS ARE NOT APPROVED. WARNING: – – – – CAUTION: DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME. – CAREFULLY OBEY THE CLEANING PROCEDURES, OR REPLACE THEM WITH A PROCEDURE WHICH IS SPECIFIED BY THE MANUFACTURER IF YOU USE EQUIVALENTS. – AFTER YOU COMPLETE THE PROCEDURE, YOU MUST PUT PROTECTIVE CAPS OR APPLICABLE PACKAGING MATERIAL ON THE PARTS. Self-explanatory B. Job Set-up Information (1) Consumable materials CODE REFERENCE DESIGNATION M49A 70030 CARECLEAN AS1 CLEANING MATERIAL (a) C. Example: - Cleaning material (M49A). Job Set-up WARNING: – THE SOLVENTS ARE DANGEROUS FOR YOUR HEALTH, AND CAN CAUSE DAMAGE TO PARTS IF THEY DETERIORATE BECAUSE OF: POLLUTION, WATER, GREASE, METAL PARTICLES, TEMPERATURE. – THE SOLVENTS MUST THUS BE FULLY CLEAN AND YOU MUST REPLACE THEM FREQUENTLY. THE CONTAINERS MUST BE FREE FROM UNWANTED PARTICLES FOR THE DIPPING AND THE SPRAYING OPERATIONS. 30-11-76 Page 4007 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series D. Procedure WARNING: – – – – DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME OR AN INCANDESCENT MATERIAL. USE THE SOLVENT BETWEEN 10 °C AND 15 °C (50 °F TO 59 °F), WHICH IS LESS THAN THE FLASH POINT. SUBTASK 30-11-76-110-001-A01 (1) Cleaning with Solvents E. (a) Put the part in the solvent momentarily, or apply the solvent to the part as a spray. If necessary, complete the cleaning with a soft brush, or with a soft piece of material (such as wood or plastic). (b) At the end of the full cleaning operation, put the part in clean solvent momentarily, or apply clean solvent to the part as a spray. (c) Dry the parts with compressed air that is clean and dry (free from dust and grease). Close-up Not applicable 30-11-76 Page 4008 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-100-807-A01 7. Procedure 3: Light Alkaline Cleaning A. Reason for the Job WARNING: – – – – CAUTION: DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME. – CAREFULLY OBEY THE CLEANING PROCEDURES, OR REPLACE THEM WITH A PROCEDURE WHICH IS SPECIFIED BY THE MANUFACTURER IF YOU USE EQUIVALENTS. – AFTER YOU COMPLETE THE PROCEDURE, YOU MUST PUT PROTECTIVE CAPS OR APPLICABLE PACKAGING MATERIAL ON THE PARTS. This procedure is specially applicable to the cleaning of Aluminum-based alloys (the recommended materials do not contain Sodium Hydroxide, which damages light alloys). B. Job Set-up Information (1) Use materials that agree with Specification MIL-TT-C-490C procedure III. (2) Example: – Cleaning material (M51A) – Cleaning material (M53A). C. Job Set-up WARNING: USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. ALKALINE MATERIALS CAUSE IRRITATION TO YOUR EYES AND YOUR SKIN. SUBTASK 30-11-76-880-002-A01 (1) Preparation D. (a) For the dilution proportions, refer to the manufacturer’s instructions. (b) Mix 5% of the material with water, at a temperature between 70 °C and 80 °C (158 °F to 176 °F). Procedure SUBTASK 30-11-76-110-002-A01 (1) Cleaning (a) Clean the parts with a lint-free cloth, which you make moist with the detergent solution. As an alternative, use a soft brush. (b) Flush the parts with clean water, at ambient temperature. CAUTION: DO NOT USE HOT AIR (100 °C (212 °F)) TO DRY SUB-ASSEMBLIES WHICH CONTAIN PRESS-FITTED PARTS. (c) Dry with low-pressure compressed air. 30-11-76 Page 4009 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series E. Close-up Not applicable 30-11-76 Page 4010 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-100-808-A01 8. Procedure 4: Cleaning of Parts with an Alcohol-Based Cleaning Agent A. Reason for the Job WARNING: – – – – CAUTION: (1) DO NOT BREATHE THE FUMES. THE SOLVENTS ARE DANGEROUS. USE EYE PROTECTION. DO NOT LET THE SOLVENTS TOUCH YOUR SKIN. CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. DO NOT CLEAN NEAR AN OPEN FLAME. – CAREFULLY OBEY THE CLEANING PROCEDURES, OR REPLACE THEM WITH A PROCEDURE WHICH IS SPECIFIED BY THE MANUFACTURER IF YOU USE EQUIVALENTS. – AFTER YOU COMPLETE THE PROCEDURE, YOU MUST PUT PROTECTIVE CAPS OR APPLICABLE PACKAGING MATERIAL ON THE PARTS. This procedure is specially applicable to: – hardware electrical component parts, – electronic component parts, – printed circuits. B. Job Set-up Information (1) Consumable Materials CODE REFERENCE DESIGNATION M09A DENATURED METHANOL (OM23214) DENATURED METHANOL C. (a) Use a cleaning material which agrees with Specification MIL-A-6090. (b) Example: - Cleaning material (M09A). Job Set-up Not applicable. Use the cleaning material as it is. D. Procedure WARNING: – IN WORKSHOPS, KEEP THE ALCOHOL-BASED CLEANING AGENTS IN SMALL QUANTITIES (250 CM 3 (15.25 CU.IN)). – CLEAN THE PARTS IN A ROOM WHERE AIRFLOW IS SUFFICIENT. – DO NOT CLEAN NEAR AN OPEN FLAME OR AN INCANDESCENT MATERIAL. SUBTASK 30-11-76-110-003-A01 (1) Cleaning E. (a) Clean parts with a soft brush. (b) Dry with compressed air which is at ambient temperature. Close-up Not applicable 30-11-76 Page 4011 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 4012 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series INSPECTION/CHECK TASK 30-11-76-200-801-A01 1. Checking Procedure A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Instrumentation DESIGNATION QTY CHARACTERISTICS OHMMETER 1 RANGE: 0 TO 1000 OHMS C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-220-002-A01 (1) Visual Inspection of Parts (a) Examine all the parts for abrasion, cracks, distortion and scratches. (b) Examine all the sealing surfaces for indentations, nicks and scratches. (c) Examine all the threads for damage. NOTE: Discard the washers, the nuts and the screws that are damaged. SUBTASK 30-11-76-280-001-A01 (2) Special Checks (a) Check of the Heating Resistors (01-140), (02-310) For type B03AA1040 1 With an ohmmeter, do a check of the resistance value of each heating resistor (01-140), (02-310) at ambient temperature (approximately 20 °C). NOTE: The measured resistance value must be equal to 423 ± 10% Ω. (b) Check of the Heating Resistor of the solenoid (01-370) For type B03AA1040 30-11-76 Page 5001 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 1 With an ohmmeter connected to the white leads, do a check of the resistance value of the heating resistor of the solenoid (01-370) at ambient temperature (approximately 20 °C). NOTE: The measured resistance value must be equal to 950 ± 10% Ω. 2 With an ohmmeter connected to the red leads, do a check of the resistance value of the solenoid (01-370) at ambient temperature (approximately 20 °C). NOTE: The measured resistance value must be equal to 100 ± 10% Ω. (c) Check of the Resistance of the Solenoid (01A-370) For type B03AA1060 1 With an ohmmeter connected to the red leads, do a check of the resistance value of the solenoid (01A-370) at ambient temperature (approximately 20 °C). NOTE: The measured resistance value must be equal to 95 ± 10% Ω. (d) Check of the insulation of the solenoïd (01-370) 1 With an ohmmeter do a check of the resistance value between the coil and the structure at ambient temperature (approximately 20 °C). NOTE: The measured resistance at 500 Vdc and the value must be more than or equal to 100 MΩ. For type B03AA1040 2 With an ohmmeter do a check of the resistance value between the two coils at ambient temperature (approximately 20 °C). NOTE: The measured resistance at 500 Vdc and the value must be more than or equal to 100 MΩ. (e) Check of the nozzle (02-230) (Ref. Fig. 5001) 1 (f) Do the dimentional check. Check of the injector (02-240) (Ref. Fig. 5002) 1 Do the dimentional check. 30-11-76 Page 5002 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 02-230B NOZZLE A A SECTION at174a01.cgm Ø 2,2 ± 0,1 mm (Dia. 0.083 to 0.090 in) A-A Check of the nozzle (02-230B) Figure 5001/GRAPHIC 30-11-76-991-027-A01 30-11-76 Page 5003 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 02-240B INJECTOR A A SECTION at173a01.cgm + 0,2 Ø 2 0 mm (Dia. 0.078 to 0.086 in) + 0,1 Ø 1 0 mm (Dia. 0.039 to 0.043 in) A-A Check of the injector (02-240B) Figure 5002/GRAPHIC 30-11-76-991-028-A01 30-11-76 Page 5004 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series E. Close-up Not applicable 30-11-76 Page 5005 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 5006 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series REPAIR TASK 30-11-76-300-801-A01 1. REPAIR No. 1: Corrosion Protection A. Reason for the Job You can repair the protection that is defective: – If there is no anodic chromic protection on small areas only. – If the area where there is no protection does not show much corrosion. This is applicable to aluminum-alloy parts. B. Job Set-up Information (1) Consumable Materials CODE REFERENCE DESIGNATION M04D ALODINE 1200 USA (MIL-C-5541A) ALOCHROME PROTECTIVE MATERIAL M01X WATER-PROOF PNR: M734C-P1200 ABRASIVE PAPER (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION TASK-30-11-76-100-803-A01 4000 CLEANING OF COMPONENT PARTS C. Job Set-up SUBTASK 30-11-76-160-004-A01 (1) Removal of the Corrosion (a) Clean the defective parts (Ref. TASK 30-11-76-100-803-A01). (b) Remove all signs of corrosion with abrasive paper (M01X). SUBTASK 30-11-76-380-001-A01 (2) Preparation of the Solution for Alochrome Treatment (a) Make a solution with 15 g (0.53 oz) of alochrome protective material (M04D) for each liter of water. NOTE: Make sure that the solution is always at ambient temperature. (b) D. Mix the solution until fully dissolved. Procedure SUBTASK 30-11-76-380-002-A01 (1) Alochrome Treatment (a) Apply the solution with a brush on the areas without protection. 30-11-76 Page 6001 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series E. (b) Let the solution dry for 3 to 4 minutes. (c) Flush with cold water. (d) Let dry in ambient air. Close-up Not applicable 30-11-76 Page 6002 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-300-802-A01 2. REPAIR No. 2: Electrical Bonding For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Do the electrical bonding operation that is applicable at the bonding point (Ref. Fig. 6001 and Ref. Fig. 6002). You can repair the bonding area of the re-used part if necessary. B. Job Set-up Information (1) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-009-A01 6000 FIGURE 6001 GRAPHIC-30-11-76-991-010-A01 6000 FIGURE 6002 C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-320-002-A01 (1) Electrical Bonding Operation (a) The different assemblies are identified with a figure engraved in the symbol. This symbol shows the electrical bonding operations that are necessary (Ref. Fig. 6002). (b) Spotfacing (S) Spotface the three holes dia. 6,5 mm (0.26 in) of the plate (01-200) with the applicable spotfacing tool. The spotfacing depth must be less than 0,1 mm (0.004 in). E. Close-up Not applicable 30-11-76 Page 6003 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 01-200 PLATE 01-230 SCREW 01-220 NUT 02-210 NOZZLE S/A 02-220B SCREW or 02-210B NOZZLE S/A 02-225 SCREW 01-420 BONDING BRAID LENGHT: 80 mm (3.15 in) LENGHT: 25 mm (0.98 in) LENGHT:105 mm (4.133 in) LENGHT: 95 mm (3.74 in) LENGHT: 95 mm (3.74 in) 01-180B or 01-180C PRESSURE SWITCH 01-130 SCREW at031b01.cgm 01-430 BONDING PLATE 01-290 SCREW Bonding Braids (For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) Figure 6001/GRAPHIC 30-11-76-991-009-A01 30-11-76 Page 6004 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 02-220B SCREW (FOR NOZZLE S/A (02-210)) or 02-225 SCREW (FOR NOZZLE S/A (02-210B)) 01-290 SCREW 01-120 PLATE 01-130 SCREW 01-200 PLATE 01-220 NUT at033b01.cgm 01-230 SCREW Electrical Bonding (For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) Figure 6002/GRAPHIC 30-11-76-991-010-A01 30-11-76 Page 6005 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-300-802-B01 3. REPAIR No. 2: Electrical Bonding For PNR B03AA1060, B03AA1060 Amdt A, B A. Reason for the Job Do the electrical bonding operation that is applicable at the bonding point (Ref. Fig. 6003 and Ref. Fig. 6004). You can repair the bonding area of the re-used part if necessary. B. Job Set-up Information (1) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-009-B01 6000 FIGURE 6003 GRAPHIC-30-11-76-991-010-B01 6000 FIGURE 6004 C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-320-001-B01 (1) Electrical Bonding Operation (a) The different assemblies are identified with a figure engraved in the symbol. This symbol shows the electrical bonding operations that are necessary (Ref. Fig. 6004). (b) Spotfacing (S) Spotface the three holes dia. 6,5 mm (0.26 in) of the plate (01A-200) with the applicable spotfacing tool. The spotfacing depth must be less than 0,1 mm (0.004 in). E. Close-up Not applicable 30-11-76 Page 6006 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 02A-210 NOZZLE S/A 02A-220B SCREW or 02A-210B NOZZLE S/A 02A-225 SCREW 01A-200 PLATE 01A-230 SCREW 01A-220 NUT LENGHT: 105 mm (4.133 in) 01A-420 BONDING BRAID LENGHT: 80 mm (3.15 in) LENGHT: 25 mm (0.98 in) LENGHT: 95 mm (3.74 in) at032b01.cgm 01A-430 BONDING PLATE 01A-290 SCREW Bonding Braids (for PNR B03AA1060, B03AA1060 Amdt A, B) Figure 6003/GRAPHIC 30-11-76-991-009-B01 30-11-76 Page 6007 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series 02A-220B SCREW (FOR NOZZLE S/A (02A-210)) or 02A-225 SCREW (FOR NOZZLE S/A (02A-210B)) 01A-290 SCREW 01A-200 PLATE 01A-220 NUT at034b01.cgm 01A-230 SCREW Electrical Bonding (For PNR B03AA1060, B03AA1060 Amdt A, B) Figure 6004/GRAPHIC 30-11-76-991-010-B01 30-11-76 Page 6008 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series ASSEMBLY TASK 30-11-76-440-801-A01 1. Assembly of the Dual Distributor Valve (01-001) (Ref. IPL Fig. 01) For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Instrumentation DESIGNATION QTY CHARACTERISTICS PRESSURE GAGE 1 RANGE: 0 TO 5 BAR REL. (0 TO 72.51 PSIG) ACCURACY 1% FLOWMETER 1 RANGE: 0 TO 5 L/MIN (0 TO 0.177 CU.FT/MIN) NOTE: The value written after the item shows the measurement capacity of the item. (b) Energy Sources DESIGNATION QTY CHARACTERISTICS ELECTRICAL POWER SUPPLY 1 28 VDC / 2 A STABILIZED PNEUMATIC SUPPLY 1 RANGE: 0 TO 10 BAR REL. (145 PSIG) AIR PRESSURE (c) Special Tools CODE REFERENCE QTY DESIGNATION T03 M82000232 1 TEST TOOL (d) Consumable Material CODE REFERENCE DESIGNATION M44X FLUIDEL 5 NORMALE SN60PB DIA 10/10 SOLDERING MATERIAL 30-11-76 Page 7001 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-011-A01 7000 FIGURE 7001 GRAPHIC-30-11-76-991-012-A01 7000 FIGURE 7002 GRAPHIC-30-11-76-991-013-A01 7000 FIGURE 7003 GRAPHIC-30-11-76-991-014-A01 7000 FIGURE 7004 GRAPHIC-30-11-76-991-024-A01 10000 IPL FIGURE 01 C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-080-001-A01 (1) Preparation of the Wiring (a) Cut the wires of the heating resistors (01-140) and (02-310) to the applicable length (Ref. Fig. 7001). (b) Put reference marks on the four heating resistors. (c) Strip the wires on a length of 4 (0 / + 0,8) mm (0.16 to 0.19 in). (d) Crimp one contact (01-390) at each end of the wires (Ref. Fig. 7001). (e) Cut one piece of white wire (01-400) of 60 mm (2.36 in). (f) Strip the wire at each end. (g) Crimp one contact (01-390) at each end. (h) Cut two pieces of white wire (01-400) of 135 mm (5.31 in) (Ref. Fig. 7002). 1 Strip each end on a length of 4 (0 / + 0,8) mm (0.16 to 0.19 in). 2 Crimp one contact (01-390) at one end of each wire. 3 Tin the other end of the wire and solder it on the pins A and B of the connector (C) (01-040) with soldering material (M44X). 4 Install a heat-shrinkable sleeve (01-410) with a length of 10 mm (0.39 in) on each wire. 5 Heat-shrink the sleeve on the solder. 30-11-76 Page 7002 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 01-140 HEATING RESISTANCES LENGHT: 75 mm (2.95 in) 2P LENGHT: 70 mm (2.76 in) 1P LENGHT: 55 mm (2.16 in) LENGHT: 100 mm (3.94 in) 2T LENGHT: 100 mm (3.94 in) LENGHT: 120 mm (4.72 in) LENGHT: 120 mm (4.72 in) 1T LENGHT: 60 mm (2.36 in) 02-310 HEATING RESISTANCES E B G A Y F J K at035b01.cgm 01-390 CONTACT Heating Resistances (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) Figure 7001/GRAPHIC 30-11-76-991-011-A01 30-11-76 Page 7003 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 01-040 CONNECTOR C A B C 01-410 HEAT SLEEVE SHRINKABLE 10 mm (0.39 in) at036b01.cgm 01-400 WHITE ELECTRICAL WIRES 135 mm (5.31 in) Wiring Circuit of the Heating Circuit (For Types B03AA1040, B03AA1040 Amdt A, B, C, D, E, F) Figure 7002/GRAPHIC 30-11-76-991-012-A01 30-11-76 Page 7004 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series SUBTASK 30-11-76-440-001-A01 (2) Assembly of the Solenoid Valves (Ref. Fig. 7003) (a) Cut the two red wires of each coil (Ref. Fig. 7009 Sheet 2/2). (b) Strip each end of the wires on a length of 4 (0 / + 0,8) mm (0.16 to 0.19 in). (c) Tin the stripped ends with solder material (M44X). (d) Cut the two white wires of the coil (Ref. Fig. 7009 Sheet 1/2 and 2/2). (e) Strip the white wires of the coil on a length of 4 (0 / + 0,8) mm (0.16 to 0.19 in) and crimp the contact (01-390) on each wire. (f) Install a heat-shrinkable sleeve with a length of 10 mm (0.39 in) at each end of the wire. (g) Heat-shrink the sleeves. (h) Install a knurled nail (01-300) on the body (01-280) with a rivet snap. (i) Install the eight shims (01-310) at the bottom of the body (01-280). (j) Install the coil (01-370) in the body and make sure that the position is correct (Ref. Fig. 7003). (k) Prepare the core (01-350) (Ref. Fig. 7003) 1 Install the knurled nail (01-300) on the core (01-350) and make sure that: Z = A - 0,1 ± 0,05 mm (0.002 to 0.006 in) (A = thickness of the diaphragm (01-360)) (l) Install the diaphragm (01-360) on the core (01-350). (m) Install the equipped core in the coil (01-370). (n) Diaphragm adjustment (Ref. Fig. 7003) 1 Find the quantity of shims (01-310) necessary to get 0,1 mm < X < 0,15 mm (0.00394 in < X < 0.0059 in), (X = D - C). NOTE: The thickness of the shim is 0,05 mm (0.00197 in). (o) Remove the core (01-350) and the coil (01-370). (p) If necessary, change the quantity of shims (01-310) installed at the bottom of the body to adjust the "X" value. (q) Examine the “X” value. (r) Install the coil (01-370) with the wires in the correct direction (Ref. Fig. 7003). (s) Install one shim (01-330). (t) Install the two shims (01-340) and the spring (01-320) in the equipped core. 30-11-76 Page 7005 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (u) Install the equipped core in the coil (01-370). NOTE: Do the same procedure for the other solenoid valve. 30-11-76 Page 7006 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PREPARATION OF THE CORE (01-350) 01-300 NAIL KNURLD Z 01-350 CORE ORIENTATION OF THE COIL (01-370B) or (01-370C) 01-300 NAIL KNURLD 01-300 NAIL KNURLD ELECTRICAL WIRES ELECTRICAL WIRES 01-280 BODY 01-370 COIL 01-280 BODY 01-370 COIL "A" WAY "B" WAY DIAPHRAGM ADJUSTMENT (01-360) X C D at037b01.cgm 01-310 SHIM Preparation of the Core (01-350), Installation of the Coil (01-370) and Adjustment of the Diaphragm (01-360) Figure 7003/GRAPHIC 30-11-76-991-013-A01 30-11-76 Page 7007 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series SUBTASK 30-11-76-420-001-A01 (3) Preliminary Installation (a) Install the bonding plate (01-430) on the cover (02-040). (b) Put the two solenoid valves with the wires, on their related ways, through the holes of the cover. (c) Install the four screws (01-290). SUBTASK 30-11-76-700-003-A01 (4) Self-Opening Test of the Solenoid Valve (Ref. Fig. 7004) (a) Install the equipped cover (02-040) on the test tool (T03). NOTE: Do not energize the solenoid. (b) Apply a pressure of 2,4 bar maximum (34.80 psi maximum) on the test tool (T03). (c) Record the value of the pressure when the flowrate is more than 0,5 l/min (0.017 cu.ft/min). (d) If the pressure is more than 2,4 bar (34.80 psi), remove one shim (01-340). (e) If the pressure is less than 2,2 bar (31.90 psi), add one shim (01-340). NOTE: Do the same procedure for the other solenoid valve. E. Close-up Not applicable 30-11-76 Page 7008 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series RED WIRES 02-040 COVER EQUIPPED RED WIRES WHITE WIRES WHITE WIRES SOLENOID VALVE PRESSURE GAGE 0 - 5 bar rel. (0 to 72.51 psig) T03 TEST TOOL 0 SHUT-OFF VALVE AIR SUPPLY 0 -10 bar rel. (0 to 145 psig) at038b01.cgm FLOWMETER 0 - 5 l/min (0 to 0.176 cu.ft/min) Self-Opening Test of the Solenoid Valve Figure 7004/GRAPHIC 30-11-76-991-014-A01 30-11-76 Page 7009 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-700-802-A01 2. Test of the Solenoid Valve (Ref. IPL Fig. 01) For PNR B03AA1040, B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Instrumentation DESIGNATION QTY CHARACTERISTICS PRESSURE GAGE 1 RANGE: 0 TO 5 BAR REL. (0 TO 72.51 PSIG) ACCURACY 1% FLOWMETER 1 RANGE: 0 TO 50 L/MIN (0 TO 1.77 CU.FT/MIN) FLOWMETER 1 RANGE: 0 TO 10 L/H (0 TO 0.35 CU.FT/H) NOTE: The value written after the item shows the measurement capacity of the item. (b) Energy Sources DESIGNATION QTY CHARACTERISTICS ELECTRICAL POWER SUPPLY 1 28 VDC / 2 A STABILIZED PNEUMATIC SUPPLY 1 RANGE: 0 TO 6 BAR REL. (87 PSIG) AIR PRESSURE (c) Special Tools CODE REFERENCE QTY DESIGNATION T03 M82000232 1 TEST TOOL (d) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL M50B RHODORSIL CAF 730 SEALING MATERIAL (2) Referenced Information 30-11-76 Page 7010 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-015-A01 7000 FIGURE 7005 GRAPHIC-30-11-76-991-024-A01 10000 IPL FIGURE 01 TASK-30-11-76-820-802-A01 8000 TABLE OF TIGHTENING TORQUES C. Job set-up Not applicable D. Procedure SUBTASK 30-11-76-700-004-A01 (1) Functional Test of the Solenoid Valve (a) Install the equipped cover on the test tool (T03) (Ref. Fig. 7005). (b) Supply a pressure of 1400 ± 10 mbar (20.16 to 20.45 psi) to the assembly. (c) Energize the solenoid valve more than one time at 28 Vdc on the two red wires. (d) Examine the values that follow: 1 Solenoid valve energized: Flowrate “Q” more than or equal to 30 l/min (1.06 cu.ft/min). 2 De-energize the solenoid valve and make sure that the flowrate is immediately equal to zero. NOTE: If the value is out of tolerance, change the number of shims (01-340). 3 Solenoid not energized: Flowrate “Q” less than or equal to 6 l/h (0.21 cu.ft/h). NOTE: If the value is out of tolerance, do a check for correct condition of the diaphragm and clean the seat. (e) Remove and replace one by one each of the four screws (01-290). NOTE: Do the same procedure for the other solenoid valve. (f) Attach the lug of the bonding braid (01-420) with the screw (01-290) and torque to the specified value (Ref. TASK 30-11-76-820-802-A01). (g) Apply sealing material (M14B) on the three remaining screws (01-290). (h) Install the three screws (01-290) and torque them to the specified value (Ref. TASK 30-11-76-820-802-A01). SUBTASK 30-11-76-410-001-A01 (2) Installation of the connector (01-040) (For PNR B03AA1040 Amdt B, C, D, E, F) (a) Turn the connector (01-040) with the two wires in accordance with its vertical axis. 30-11-76 Page 7011 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (b) Apply a layer of the sealing material (M50B) on the connector pins, heat shrinkable and a part of the electrical wires. (c) After three hours make sure that of the polymerization of the sealing material (M50B). (d) Apply sealing material (M14B) on the four screws (01-050). (e) Attach the connector (01-040) with the four screws (01-050) on the cover (02-040). NOTE: Make sure that the orientation of the connector (01-040) on the cover (02-040) is correct. (f) E. Torque the four screws to the specified value (Ref. TASK 30-11-76-820-802-A01). Close-up Not applicable 30-11-76 Page 7012 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PRESSURE GAGE 0 - 5 bar rel. (0 to 72.51 psig) SHUT-OFF VALVE AIR SUPPLY 0 -10 bar rel. (0 to 145 psig) 0 FLOWMETER 0 - 50 l/min (0 to 1.77 cu.ft/min) 02-040 COVER EQUIPPED FLOWMETER 0 - 10 l/h (0 to 0.353 cu.ft/h) ELECTRICAL POWER SUPPLY 28 Vdc 0V + 28 Vdc V RED WIRES RED WIRES WHITE WIRES WHITE WIRES SOLENOID VALVE T03 at039b01.cgm TEST TOOL Test of the Solenoid Valve Figure 7005/GRAPHIC 30-11-76-991-015-A01 30-11-76 Page 7013 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-440-802-A01 3. Assembly of the Dual Valves (Ref. Fig. 7006) For PNR B03AA1040 and B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Special Tools CODE REFERENCE QTY DESIGNATION T01 M65724395 1 SUPPORT (b) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL M01C GRAPHITE POWDER F (AIR4224) USA (SS-G-659A) LUBRICATING MATERIAL M05C GREASE MAGNALUBE G USA (MIL-G-23549) LUBRICATING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-025-A01 10000 IPL FIGURE 02 TASK-30-11-76-820-802-A01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-440-002-A01 (1) Assembly of the Dual Valve (a) Install the axle (02-200) on the equipped diaphragm (02-180). (b) Install the nut (02-190) and torque it to the specified value (Ref. TASK 30-11-76-820-802-A01). (c) Apply lubricating material (M01C) on the preformed packing (02-160). (d) Install the preformed packing (02-160) on the equipped valve (02-170). 30-11-76 Page 7014 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (e) Install the equipped valve (02-170) with the preformed packing (02-160) on the axle (02-200). (f) Install the washer (02-150). (g) Install this sub-assembly in the body (02-340). (h) Install this sub-assembly on the support (T01). (i) On the axle, install: (j) 1 One spacer (02-140). 2 One upper flange (02-130). 3 One valve (02-110) and one washer (02-120). 4 One lower flange (02-090). Install the nuts (02-100) and (02-190) and torque them to the specified value (Ref. TASK 30-11-76-820-802-A01). NOTE: The nuts have not the same tightening torque. (k) Apply lubricating material (M01C) on the preformed packing (02-080). (l) Install the preformed packing (02-080) in the groove of the guide (02-070). (m) Install the equipped guide. (n) Apply lubricating material (M05C) on the two silent blocks (02-030). (o) Install the two silent blocks (02-030) on the plate (02-010). (p) Apply sealing material (M14B) on the screw (02-020). (q) Attach the equipped plate to the body with the screw (02-020) and torque to the specified value (Ref. TASK 30-11-76-820-802-A01). NOTE: Do the same procedure for the other dual valve. E. Close-up Not applicable 30-11-76 Page 7015 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 02-020 02-030 02-080 02-090 02-110 02-010 02-140 02-070 02-100 02-150 02-120 02-170 02-130 02-200 02-180 02-190 02-160 at112a01.cgm 02-340 Assembly of the Dual Valves Figure 7006/GRAPHIC 30-11-76-991-029-A01 30-11-76 Page 7016 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 7017 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-440-803-A01 4. Assembly and Installation of the Nozzle S/A (02-210) and (02-210B) and the Heating Resistors (02-310), (1T), (2T) (Ref. IPL Fig. 02) For PNR B03AA1040 and B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL M50B RHODORSIL CAF 730 SEALING MATERIAL M01C GRAPHITE POWDER F (AIR4224) USA (SS-G-659A) LUBRICATING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-016-A01 7000 FIGURE 7006 GRAPHIC-30-11-76-991-025-A01 10000 IPL FIGURE 02 TASK-30-11-76-820-802-A01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-440-003-A01 (1) Assembly of the Nozzle S/A (Ref. Fig. 7007) (a) Nozzle S/A (02-210) 1 Apply lubricating material (M01C) on the preformed packings (02-270) and (02-280). 2 Install the preformed packings (02-270) and (02-280) in the groove of the injector (02-240). 3 Install the springs (01-320) and the heating resistors (02-310) (Ref. Fig. 7007 VIEW A). 30-11-76 Page 7018 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 4 Install a heat-shrinkable sleeve (01-410) with a length of 10 mm (0.39 in) on the two wires of each heating resistor. 5 Heat-shrink the sleeve (01-410). 6 Fill the housings of the heating resistors with sealing material (M50B). 7 Install the equipped injector (02-240) in the nozzle (02-230). SUBTASK 30-11-76-440-003-B01 (2) Assembly of the Nozzle S/A (Ref. Fig. 7007) (a) Nozzle S/A (02-210B) 1 Apply lubricating material (M01C) on the preformed packing (02-250). 2 Install the preformed packing (02-250) on the injector (02-240B). 3 Install the equipped injector in the body (02-260). 4 Apply sealing material (M14B) on the nozzle (02-230B). 5 Install the nozzle (02-230B) and torque it to the specified value (Ref. TASK 30-11-76-820-802-A01). 6 Install a heat-shrinkable sleeve (01-410) with a length of 10 mm (0.39 in) on the two wires of each heating resistor (02-310). 7 Heat-shrink the sleeves (01-410). 8 Install the heating resistor (02-310) in the body (02-260) (Ref. Fig. 7007 VIEW B). 9 Fill the housings of the heating resistors (02-310) with sealing material (M50B). SUBTASK 30-11-76-420-002-A01 (3) Installation of the Nozzle S/A (Ref. Fig. 7007) (a) Nozzle S/A (02-210) 1 Apply lubricating material (M01C) on the preformed packings (02-290) and (02-300). 2 Install the two preformed packings (02-290) and (02-300) on the body (02-340). 3 Apply sealing material (M14B) on the three screws (02-220B). 4 Install the Nozzle S/A (02-210) and attach it with the three screws (02-220B). 5 Torque the screws (02-220B) to the specified value (Ref. TASK 30-11-76-820-802-A01). SUBTASK 30-11-76-420-002-B01 (4) Installation of the Nozzle S/A (Ref. Fig. 7007) 30-11-76 Page 7019 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (a) E. Nozzle S/A (02-210B) 1 Apply lubricating material (M01C) on the preformed packings (02-290) and (02-300). 2 Install the two preformed packings (02-290) and (02-300) on the body (02-340). 3 Apply sealing material (M14B) on the three screws (02-220). 4 Install the body (02-260) and attach it with the two screws (02-220). 5 Torque the screws (02-220) to the specified value (Ref. TASK 30-11-76-820-802-A01). 6 Install the screw (02-225) with one wire of the bonding braid (01-420) and torque it to the specified value (Ref. TASK 30-11-76-820-802-A01). Close-up Not applicable 30-11-76 Page 7020 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 02-230B 02-260 02-220 02-225 02-210B 02-310 02-240B 02-300 02-250 02-290 A 02-230 02-220B 02-320 02-310 02-270 02-280 02-240 02-300 02-210 02-290 02-340 B A B HEATING RESISTANCES OF THE NOZZLE S/A (02-210B) HEATING RESISTANCES OF THE NOZZLE S/A (02-210) M50B SEALING MATERIAL 02-310 HEATING RESISTOR (1T) 02-310 HEATING RESISTOR (1T) 02-260 BODY 02-230 NOZZLE 02-310 HEATING RESISTOR (2T) 02-310 HEATING RESISTOR (2T) at040b01.cgm M50B SEALING MATERIAL Assembly and Installation of the Nozzle S/A (02-210) and (02-210B) Figure 7007/GRAPHIC 30-11-76-991-016-A01 30-11-76 Page 7021 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-801-A01 5. Installation of the Cover (02-040) and the Plate (01-200) (Ref. IPL Fig. 01 and Ref. IPL Fig. 02) For PNR B03AA1040 and B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-024-A01 10000 IPL FIGURE 01 GRAPHIC-30-11-76-991-025-A01 10000 IPL FIGURE 02 TASK-30-11-76-820-802-A01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-003-A01 (1) Installation of the Cover (02-040) (a) Install the two springs (02-060) on the diaphragm (02-180). (b) Install the wires of the two heating resistors and the connector (01-040) through the cover (02-040). (c) Apply sealing material (M14B) on the eight screws (02-050). (d) Attach the cover (02-040) with the eight screws (02-050). (e) Torque the screws (02-050) to the specified value (Ref. TASK 30-11-76-820-802-A01). SUBTASK 30-11-76-420-004-A01 (2) Installation of the Plate (01-200) (a) Install one wire of the bonding braid (01-420) on the plate and attach it with one screw (01-230) and one nut (01-220). 30-11-76 Page 7022 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series E. (b) Torque the screws (01-230) to the specified value (Ref. TASK 30-11-76-820-802-A01). (c) Apply sealing material (M14B) on the five screws (01-210). (d) Install the plate (01-200) on the unit and attach it with the five screws (01-210). (e) Torque the screws to the specified value (Ref. TASK 30-11-76-820-802-A01). Close-up Not applicable 30-11-76 Page 7023 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-802-A01 6. Installation of the Pressure Switches and the Heating Resistors (01-140), (1P), (2P) (Ref. IPL Fig. 01) For PNR B03AA1040 and B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Special Tools CODE REFERENCE QTY DESIGNATION T02 OS22766 1 MOUNTING NOSE T04 M65725780 1 WRENCH (b) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL M50B RHODORSIL CAF730 SEALING MATERIAL M01C GRAPHITE POWDER F (AIR4224) USA (SS-G-659A) LUBRICATING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-017-A01 7000 FIGURE 7007 GRAPHIC-30-11-76-991-018-A01 7000 FIGURE 7008 GRAPHIC-30-11-76-991-024-A01 10000 IPL FIGURE 01 TASK-30-11-76-820-802-A01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-005-A01 (1) Installation of the Pressure Switches (01-180) (Ref. Fig. 7008) (a) Apply lubricating material (M01C) on the preformed packings (01-190). 30-11-76 Page 7024 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (b) With the mounting hose (T02), install the preformed packings (01-190) on the two pressure switches (01-180). (c) Apply a small quantity of sealing material (M14B) on the pressure switches (01-180). (d) Install the pressure switches (01-180) on the body (02-340). (e) Torque the pressure switches with the wrench (T04) to the specified value (Ref. TASK 30-11-76-820-802-A01). (f) Install the body (01-150) with the wiring path groove pointed to the body (02-340). (g) Attach the body (01-150) with the two screws (01-170) and the two nuts (01-160). (h) Torque the screws (01-170) to the specified value (Ref. TASK 30-11-76-820-802-A01). SUBTASK 30-11-76-420-006-A01 (2) Installation of the Heating Resistors (1P) and (2P) (01-140) E. (a) Cut the wires of the pressure switches (Ref. Fig. 7009). (b) Strip the wires on a length of 4 (0 / + 0,8) mm (0.16 to 0.19 in). (c) Strip the ends of the wires and install a heat shrinkable sleeve with a length of 10 mm (0.39 in). (d) Install a heat-shrinkable sleeve with a length of 15 mm (0.59 in) on the two wires of the heating resistor (1P). (e) Install a heat-shrinkable sleeve with a length of 25 mm (0.98 in) on the two wires of the heating resistor (2P). (f) Heat-shrink the sleeves. (g) Install the two heating resistors (1P) and (2P) (01-140) in the body (01-150) (Ref. Fig. 7008 Detail A). (h) Apply sealing material (M14B) on the screw (01-130) with the bonding braid (01-420) installed. (i) Attach the plate (01-120) with the screw (01-130). (j) Torque the screw (01-130) to the specified value (Ref. TASK 30-11-76-820-802-A01). (k) Apply a layer of the sealing material (M50B) on the two heating resistors (01-140). (l) Apply sealing material (M14B) on the four screws (01-110). (m) Install the cover (01-100) and attach it with the four screws (01-110). (n) Torque the four screws to the specified value (Ref. TASK 30-11-76-820-802-A01). Close-up Not applicable 30-11-76 Page 7025 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 01-340 01-150 01-170 01-140 01-420 01-160 01-130 01-100 01-190 01-180B 01-120 01-110 A A 01-150 BODY HEATING RESISTOR (2P) at041b01.cgm HEATING RESISTOR (1P) Installation of the Pressure Switches and the Heating Resistors (01-140), (1P), (2P) Figure 7008/GRAPHIC 30-11-76-991-017-A01 30-11-76 Page 7026 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-803-A01 7. Installation of the Electrical wiring (Ref. IPL Fig. 01) For PNR B03AA1040 and B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Special Tools CODE REFERENCE QTY DESIGNATION T01 M65724395 1 SUPPORT (b) Consumable Materials CODE REFERENCE DESIGNATION M07B PERMABOND F245 SEALING MATERIAL M14B PR1005L SEALING COMPOUND SEALING MATERIAL M44X FLUIDEL 5 NORMALE SNPB DIA 10/10 SOLDER MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-018-A01 7000 FIGURE 7008 GRAPHIC-30-11-76-991-024-A01 10000 IPL FIGURE 01 TASK-30-11-76-820-802-A01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-007-A01 (1) Installation of the Electrical Wiring (Ref. Fig. 7009) (a) Install the electrical wiring of the pressure switches and the heating resistors in the opening of the body (01-150). (b) Solder the wires of the “A” way solenoid-valve and the pressure switch on the connector (01-060). 30-11-76 Page 7027 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (c) Solder the wires of the “B” way solenoid-valve and the pressure switch on the connector (01-080). 30-11-76 Page 7028 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series SOLENOID VALVES "A" WAY 01-040 CONNECTOR C "B" WAY B C 01-410 HEAT SLEEVE SHRINKABLE 10 mm (0.39 in) WHITE 75 mm (2.95 in) WHITE 75 mm (2.95 in) WHITE 95 mm (3.74 in) WHITE 95 mm (3.74 in) A 01-400 WHITE ELECTRICAL WIRES 135 mm (5.31 in) 01-390 CONTACT R S T U V X Y H J K L M N P A B C D E F G 02-230 NOZZLE 1T 2T 02-310 HEATING RESISTANCE 01-140 HEATING RESISTANCE 01-150 BODY (PRESSURE SWITCH) 1P 2P at042b01.cgm 01-400 WHITE ELECTRICAL WIRE 01-380 JUNCTION MODULE Installation of the electrical wiring (Sheet 1 of 2) Figure 7009/GRAPHIC 30-11-76-991-018-A01 30-11-76 Page 7029 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series A B 01-060 CONNECTOR "A" WAY RED 60 mm (2.36 in) RED 60 mm (2.36 in) SOLENOID VALVE C D E 110 mm (4.33 in) or 120 mm (4.72 in) FOR TYPE B03AA1040 Amdt E and Amdt F 110 mm (4.33 in) or 120 mm (4.72 in) FOR TYPE B03AA1040 Amdt E and Amdt F PRESSURE SWITCH F A B 60 mm (2.36 in) RED 60 mm (2.36 in) SOLENOID VALVE C D E 130 mm (5.12 in) or 140 mm (5.51 in) FOR TYPE B03AA1040 Amdt E and Amdt F 130 mm (5.12 in) or 140 mm (5.51 in) FOR TYPE B03AA1040 Amdt E and Amdt F PRESSURE SWITCH F at047b01.cgm 01-080 CONNECTOR "B" WAY RED Installation of the electrical wiring (Sheet 2 of 2) Figure 7009/GRAPHIC 30-11-76-991-018-A01 30-11-76 Page 7030 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series SUBTASK 30-11-76-420-008-A01 (2) Installation of the Connectors (01-060) and (01-080) (a) Install the dual distributor valve on the support (T01). (b) Do all the connections with the junction module (01-380) (Ref. Fig. 7009). (c) Make sure that the connections are correct. (d) Make sure that the resistance between the pins of the connector (01-040) is equal to 225 ± 22 Ω. (e) Apply sealing material (M14B) on the screws (01-070) and (01-090). (f) Attach the connectors (01-060) and (01-080) with the screws (01-070) and (01-090). NOTE: Control the position of the connectors (Ref. Fig. 1) and (Ref. Fig. 2). E. (g) Torque the screws to the specified value (Ref. TASK 30-11-76-820-802-A01). (h) Attach the electrical wiring with the clamp (01-415) or the lacing cord. Close-up Not applicable 30-11-76 Page 7031 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-804-A01 8. Installation of the Pressure Relief Valve and the Cover (01-010) (Ref. IPL Fig. 01) For PNR B03AA1040 and B03AA1040 Amdt A, B, C, D, E, F A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M06B CEMENT SILASTIC RTV732 SEALING MATERIAL M07B PERMABOND F245 SEALING MATERIAL M14B PR1005L SEALING COMPOUND SEALING MATERIAL M04X LOCKWIRE DIA 0,5 MM (0.019 IN) SEALING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-001-A01 1 FIGURE 1 GRAPHIC-30-11-76-991-024-A01 10000 IPL FIGURE 01 TASK-30-11-76-820-802-A01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-009-A01 (1) Installation of the Pressure Relief Valve (a) Install the valve (01-270), the spring (01-260) and the cover (01-240). (b) Apply sealing material (M14B) on the three screws (01-250). (c) Install the three screws (01-250) and torque them to the specified value (Ref. TASK 30-11-76-820-802-A01). SUBTASK 30-11-76-420-010-A01 (2) Installation of the Cover (01-010) (a) Safety the junction module (01-380) in its housing with a drop of sealing material (M06B). (b) Apply sealing material (M14B) on the three screws (01-020) and the two screws (01-030). 30-11-76 Page 7032 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (c) Install the cover (01-010) and attach it with the three screws (01-020) and the two screws (01-030). (d) Torque the screws to the specified value (Ref. TASK 30-11-76-820-802-A01). (e) Safety the two screws (01-030) (Ref. Fig. 1) with safety material (M04X). SUBTASK 30-11-76-410-002-A01 (3) Installation of the identification plate (01-450) on the cover (01-010) E. (a) Apply sealing material (M07B) on the identification plate (01-450). (b) Install the identification plate (01-450) on the cover (01-010). Close-up Not applicable 30-11-76 Page 7033 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-440-801-B01 9. Assembly of the Dual Distributor Valve (01A-001) (Ref. IPL Fig. 01A) For PNR B03AA1060, B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Materials (a) Instrumentation DESIGNATION QTY CHARACTERISTICS PRESSURE GAGE 1 RANGE: 0 TO 5 BAR REL. (0 TO 72.51 PSIG) ACCURACY 1% FLOWMETER 1 RANGE: 0 TO 4 L/MIN (0 TO 0.141 CU.FT/MIN) NOTE: The value written after the item shows the measurement capacity of the item. (b) Energy Sources DESIGNATION QTY CHARACTERISTICS ELECTRICAL POWER SUPPLY 1 28 VDC / 2 A STABILIZED PNEUMATIC SUPPLY 1 RANGE: 0 TO 10 BAR REL. (145 PSIG) AIR PRESSURE (c) Special Tools CODE REFERENCE QTY DESIGNATION T03 M82000232 1 TEST TOOL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-011-B01 7000 FIGURE 7009 GRAPHIC-30-11-76-991-012-B01 7000 FIGURE 7010 GRAPHIC-30-11-76-991-024-B01 10000 IPL FIGURE 01A C. Job Set-up Not applicable 30-11-76 Page 7034 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series D. Procedure SUBTASK 30-11-76-440-001-B01 (1) Assembly of the Solenoid Valves (Ref. Fig. 7010) (a) Cut the two wires of each solenoid valve (Ref. Fig. 7015). (b) Strip the wires on a length of 4 (+ 0,8 / 0) mm (0.16 to 0.19 in). (c) Crimp the contact pins of the connectors (01A-060) and (01A-080) with the stripped wires. (d) Install a knurled nail (01A-300) on the body (01A-280) with a rivet snap. (e) Install the eight shims (01A-310) at the bottom of the body. (f) Install the coil (01A-370) in the body and make sure that the position is correct (Ref. Fig. 7010). (g) Prepare the core (01A-350) (Ref. Fig. 7010) 1 Install the knurled nail (01A-300) on the core (01A-350) and make sure that: Z = A - 0,1 ± 0,05 mm (0.002 to 0.006 in) (A = thickness of the diaphragm (01-360)) (h) Install the diaphragm (01A-360) on the core (01A-350). (i) Install the equipped core in the coil (01A-370). (j) Diaphragm adjustment (Ref. Fig. 7010) 1 Find the quantity of shims (01A-310) necessary to get 0,1 mm < X < 0,15 mm (0.00394 in < X < 0.0059 in), (X = D - C). NOTE: The thickness of the shim is 0,05 mm (0.00197 in). (k) Remove the core (01A-350) and the coil (01A-370). (l) If necessary, change the quantity of shims (01A-310) installed at the bottom of the body to adjust the "X" value. (m) Examine the “X” value. (n) Install the coil (01A-370) with the wires in the correct direction (Ref. Fig. 7010). (o) Install one shim (01A-330). (p) Install the two shims (01A-340) and the spring (01A-320) in the equipped core. (q) Install the equipped core in the coil (01A-370). NOTE: Do the same procedure for the other solenoid valve. 30-11-76 Page 7035 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PREPARATION OF THE CORE (01A-350) 01A-300 NAIL KNURLD Z 01A-350 CORE ORIENTATION OF THE COIL (01A-370) 01A-300 NAIL KNURLD 01A-300 NAIL KNURLD ELECTRICAL WIRES ELECTRICAL WIRES 01A-280 BODY 01A-370 COIL 01A-280 BODY 01A-370 COIL "A" WAY "B" WAY DIAPHRAGM ADJUSTMENT (01A-360) X C D at043b01.cgm 01A-310 SHIM Preparation of the Core (01A-350), Installation of the Coil (01A-370) and Adjustment of the Diaphragm (01A-360) Figure 7010/GRAPHIC 30-11-76-991-011-B01 30-11-76 Page 7036 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series SUBTASK 30-11-76-420-001-B01 (2) Preliminary Installation (a) Install the bonding plate (01A-430) on the cover (02A-040). (b) Put the two solenoid valves with the wires, on their related rail, through the holes of the cover. (c) Install the four screws (01A-290). SUBTASK 30-11-76-700-003-B01 (3) Self-Opening Test of the Solenoid Valve (Ref. Fig. 7011) (a) Install the equipped cover (02A-040) on the test tool (T03). NOTE: Do not energize the solenoid. (b) Apply a pressure of 2,4 bar maximum (34.80 psi maximum) on the test tool (T03). (c) Record the value of the pressure when the flowrate is more than 0,5 l/min (0.017 cu.ft/min). (d) If the pressure is more than 2,4 bar (34.80 psi), remove one shim (01A-340). (e) If the pressure is less than 2,2 bar (31.90 psi), add one shim (01A-340). NOTE: Do the same procedure for the other solenoid valve. E. Close-up Not applicable 30-11-76 Page 7037 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 02A-040 COVER EQUIPPED RED WIRES RED WIRES SOLENOID VALVE PRESSURE GAGE 0 - 5 bar rel. (0 to 72.51 psig) T03 TEST TOOL 0 SHUT-OFF VALVE AIR SUPPLY 0 -10 bar rel. (0 to 145 psig) at044b01.cgm FLOWMETER 0 - 5 l/min (0 to 0.176 cu.ft/min) Self-Opening Test of the Solenoid Valve Figure 7011/GRAPHIC 30-11-76-991-012-B01 30-11-76 Page 7038 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-700-802-B01 10. Test of the Solenoid Valve (Ref. IPL Fig. 01A) For PNR B03AA1060 and B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Instrumentation DESIGNATION QTY CHARACTERISTICS PRESSURE GAGE 1 RANGE: 0 TO 5 BAR REL. (0 TO 72.51 PSIG) ACCURACY 1% FLOWMETER 1 RANGE: 0 TO 50 L/MIN (0 TO 1.77 CU.FT/MIN) FLOWMETER 1 RANGE: 0 TO 10 L/H (0 TO 0.35 CU.FT/H) NOTE: The value written after the item shows the measurement capacity of the item. (b) Energy Sources DESIGNATION QTY CHARACTERISTICS ELECTRICAL POWER SUPPLY 1 28 VDC / 2 A STABILIZED PNEUMATIC SUPPLY 1 RANGE: 0 TO 6 BAR REL. (87 PSIG) AIR PRESSURE (c) Special Tools CODE REFERENCE QTY DESIGNATION T03 M82000232 1 TEST TOOL (d) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-015-B01 7000 FIGURE 7011 GRAPHIC-30-11-76-991-024-B01 10000 IPL FIGURE 01A TASK-30-11-76-820-802-B01 8000 TABLE OF TIGHTENING TORQUES 30-11-76 Page 7039 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series C. Job set-up Not applicable D. Procedure SUBTASK 30-11-76-700-004-B01 (1) Functional Test of the Solenoid Valve (a) Install the equipped cover on the test tool (T03) (Ref. Fig. 7012). (b) Supply a pressure of 1400 ± 10 mbar (20.16 to 20.45 psi) to the assembly. (c) Energize the solenoid valve more than one time. NOTE: Apply 28 Vdc on the two red wires. (d) Examine the values that follow: 1 Solenoid valve energized: Flowrate “Q” more than or equal to 30 l/min (1.06 cu.ft/min). 2 De-energize the solenoid valve and make sure that the flowrate is immediately equal to zero. NOTE: If the value is out of tolerance, change the number of shims (01A-340). 3 Solenoid not energized: Flowrate “Q” less than or equal to 6 l/h (0.21 cu.ft/h). NOTE: If the value is out of tolerance, do a check for correct condition of the diaphragm and clean the seat. (e) Remove and replace one by one each of the four screws (01A-290). NOTE: Do the same procedure for the other solenoid valve. E. (f) Attach the lug of the bonding braid (01A-420) with the screw (01A-290) and torque to the specified value (Ref. TASK 30-11-76-820-802-B01). (g) Apply locking material (M14B) on the three remaining screws (01A-290). (h) Install the three screws (01A-290) and torque them to the specified value (Ref. TASK 30-11-76-820-802-B01). (i) Apply locking material (M14B) on the four screws (01A-050). (j) Attach the plate (01A-040) with the four screws (01A-050) (Ref. Fig. 7012). (k) Torque the four screws to the specified value (Ref. TASK 30-11-76-820-802-B01). Close-up Not applicable 30-11-76 Page 7040 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PRESSURE GAGE 0 - 5 bar rel. (0 to 72.51 psig) SHUT-OFF VALVE AIR SUPPLY 0 -10 bar rel. (0 to 145 psig) 0 FLOWMETER 0 - 50 l/min (0 to 1.77 cu.ft/min) 02A-040 COVER EQUIPPED FLOWMETER 0 - 10 l/h (0 to 0.353 cu.ft/h) ELECTRICAL POWER SUPPLY 28 Vdc 0V + 28 Vdc V RED WIRES RED WIRES SOLENOID VALVE T03 at045b01.cgm TEST TOOL Test of the Solenoid Valve Figure 7012/GRAPHIC 30-11-76-991-013-B01 30-11-76 Page 7041 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-440-802-B01 11. Assembly of the Dual Valves (Ref. Fig. 7013) For PNR B03AA1060 and B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Special Tools CODE REFERENCE QTY DESIGNATION T01 M65724395 1 SUPPORT (b) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL M01C GRAPHITE POWDER F (AIR4224) USA (SS-G-659A) LUBRICATING MATERIAL M05C GREASE MAGNALUBE G USA (MIL-G-23549) LUBRICATING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-025-B01 10000 IPL FIGURE 02A TASK-30-11-76-820-802-B01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-440-002-B01 (1) Assembly of the Dual Valve (a) Install the axle (02A-200) on the equipped diaphragm (02A-180). (b) Install the nut (02A-190) and torque it to the specified value (Ref. TASK 30-11-76-820-802-B01). (c) Apply lubricating material (M01C) on the preformed packing (02A-160). (d) Install the preformed packing (02A-160) on the equipped valve (02A-170). 30-11-76 Page 7042 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (e) Install the equipped valve (02A-170) with the preformed packing (02A-160) on the axle (02A-200). (f) Install the washer (02A-150). (g) Install this sub-assembly in the body (02A-340). (h) Install this sub-assembly on the support (T01). (i) On the axle, install: (j) 1 One spacer (02A-140). 2 One upper flange (02A-130). 3 One valve (02A-110) and one washer (02A-120). 4 One lower flange (02A-090). Install the nuts (02A-100) and (02A-190) and torque them to the specified value (Ref. TASK 30-11-76-820-802-B01). NOTE: The nuts have not the same tightening torque. (k) Apply lubricating material (M01C) on the preformed packing (02A-080). (l) Install the preformed packing (02A-080) in the groove of the guide (02A-070). (m) Install the equipped guide. (n) Apply lubricating material (M05C) on the two silent blocks (02A-030). (o) Install the two silent blocks (02A-030) on the plate (02A-010). (p) Apply locking material (M14B) on the screw (02A-020). (q) Attach the equipped plate to the body with the screw (02A-020) and torque to the specified value (Ref. TASK 30-11-76-820-802-B01). NOTE: Do the same procedure for the other dual valve. E. Close-up Not applicable 30-11-76 Page 7043 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 02A-020 02A-030 02A-080 02A-090 02A-110 02A-010 02A-140 02A-070 02A-100 02A-150 02A-120 02A-170 02A-130 02A-200 02A-180 02A-190 02A-160 at048b01.cgm 02A-340 Assembly of the Dual Valves Figure 7013/GRAPHIC 30-11-76-991-030-A01 30-11-76 Page 7044 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 7045 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-440-803-B01 12. Assembly and Installation of the Nozzle S/A (02A-210) and (02A-210B) (Ref. IPL Fig. 02A) For PNR B03AA1060 and B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL M01C GRAPHITE POWDER F (AIR4224) USA (SS-G-659A) LUBRICATING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-016-B01 7000 FIGURE 7012 GRAPHIC-30-11-76-991-025-B01 10000 IPL FIGURE 02A TASK-30-11-76-820-802-B01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-440-003-C01 (1) Assembly of the Nozzle S/A (Ref. Fig. 7014) (a) Nozzle S/A (02A-210) 1 Apply lubricating material (M01C) on the preformed packings (02A-270) and (02A-280). 2 Install the preformed packings (02A-270) and (02A-280) in the groove of the injector (02A-240). 3 Install the equipped injector (02A-240) in the nozzle (02A-230). SUBTASK 30-11-76-440-003-D01 (2) Assembly of the Nozzle S/A (Ref. Fig. 7014) 30-11-76 Page 7046 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (a) Nozzle S/A (02A-210B) 1 Apply lubricating material (M01C) on the preformed packing (02A-250). 2 Install the preformed packing (02A-250) in the groove of the injector (02A-240B). 3 Install the equipped injector in the body (02A-260). 4 Apply locking material (M14B) on the nozzle (02A-230B). 5 Install the nozzle (02A-230B) and torque it to the specified value (Ref. TASK 30-11-76-820-802-B01). SUBTASK 30-11-76-420-002-C01 (3) Installation of the Nozzle S/A (Ref. Fig. 7014) (a) Nozzle S/A (02A-210) 1 Apply lubricating material (M01C) on the preformed packings (02A-290) and (02A-300). 2 Install the two preformed packings (02A-290) and (02A-300) on the body (02A-340). 3 Apply locking material (M14B) on the three screws (02A-220B). 4 Install the Nozzle S/A (02A-210) and attach it with the three screws (02A-220B). 5 Torque the screws (02A-220B) to the specified value (Ref. TASK 30-11-76-820-802-B01). SUBTASK 30-11-76-420-002-D01 (4) Installation of the Nozzle S/A (Ref. Fig. 7014) (a) E. Nozzle S/A (02A-210B) 1 Apply lubricating material (M01C) on the preformed packings (02A-290) and (02A-300). 2 Install the two preformed packings (02A-290) and (02A-300) on the body (02A-340). 3 Apply locking material (M14B) on the two screws (02A-220). 4 Install the body (02A-260) and attach it with the two screws (02A-220). 5 Torque the screws (02A-220) to the specified value (Ref. TASK 30-11-76-820-802-B01). 6 Install the screw (02A-225) with one wire of the bonding braid (01A-420) and torque it to the specified value (Ref. TASK 30-11-76-820-802-B01). Close-up Not applicable 30-11-76 Page 7047 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 02A-230B 02A-260 02A-220 02A-225 02A-210B 02A-240B 02A-250 02A-300 02A-290 02A-220B 02A-230 02A-300 02A-270 02A-280 02A-210 02A-240 02A-290 at113b01.cgm 02A-340 Assembly and Installation of the Nozzle S/A (02A-210) and (02A-210B) Figure 7014/GRAPHIC 30-11-76-991-016-b01 30-11-76 Page 7048 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-801-B01 13. Installation of the Cover (02A-040) and the Plate (01A-200) (Ref. IPL Fig. 01A and Ref. IPL Fig. 02A) For PNR B03AA1060 and B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-024-B01 10000 IPL FIGURE 01A GRAPHIC-30-11-76-991-025-B01 10000 IPL FIGURE 02A TASK-30-11-76-820-802-B01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-003-B01 (1) Installation of the Cover (02A-040) (a) Install the two springs (02A-060) on the diaphragm (02A-180). (b) Apply sealing material (M14B) on the eight screws (02A-050). (c) Attach the cover (02A-040) with the eight screws (02A-050). (d) Torque the screws (02A-050) to the specified value (Ref. TASK 30-11-76-820-802-B01). SUBTASK 30-11-76-420-004-B01 (2) Installation of the Plate (01A-200) (a) Install one wire of the bonding braid (01A-420) on the plate and attach it with one screw (01A-230) and one nut (01A-220). (b) Torque the screws (01A-230) to the specified value (Ref. TASK 30-11-76-820-802-B01). (c) Apply sealing material (M14B) on the five screws (01A-210). 30-11-76 Page 7049 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series E. (d) Install the plate (01A-200) on the unit and attach it with the five screws (01A-210). (e) Torque the screws to the specified value (Ref. TASK 30-11-76-820-802-B01). Close-up Not applicable 30-11-76 Page 7050 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-802-B01 14. Installation of the Threaded Plugs (01A-170) (Ref. IPL Fig. 01A) For PNR B03AA1060 and B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL M01C GRAPHITE POWDER F (AIR4224) USA (SS-G-659A) LUBRICATING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-024-B01 10000 IPL FIGURE 01A TASK-30-11-76-820-802-B01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-005-B01 (1) Installation of the Threaded Plugs (01A-170) E. (a) Apply lubricating material (M01C) on the preformed packings (01A-190). (b) Install a preformed packing (01A-190) on the threaded plug (01A-170). (c) Apply a small quantity of locking material (M14B) on the threaded plugs (01A-170). (d) Torque the threaded plugs (01A-170) to the specified value (Ref. TASK 30-11-76-820-802-B01). Close-up Not applicable 30-11-76 Page 7051 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-803-B01 15. Installation of the Electrical wiring (Ref. IPL Fig. 01A) For PNR B03AA1060 and B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M14B PR1005L SEALING COMPOUND SEALING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-018-B01 7000 FIGURE 7013 GRAPHIC-30-11-76-991-024-B01 10000 IPL FIGURE 01A TASK-30-11-76-820-802-B01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-007-B01 (1) Installation of the Electrical Wiring (Ref. Fig. 7015) (a) Install the contact pins in the connectors (01A-080) and (01A-060). (b) Install the spacer (01A-095). (c) Connect the wires to the connectors (01A-060 “A” way) and (01A-080 “B” way). (d) Apply locking material (M14B) on the screws (01A-070) and (01A-090). (e) Install the connectors with the screws (01A-070) and (01A-090). NOTE: Control the position of the connectors (Ref. Fig. 1) and (Ref. Fig. 2). (f) Torque to the specified value (Ref. TASK 30-11-76-820-802-B01). 30-11-76 Page 7052 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series E. Close-up Not applicable 30-11-76 Page 7053 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 1 2 01A-060 CONNECTOR "A" WAY RED 60 mm (2.36 in) RED 60 mm (2.36 in) RED 60 mm (2.36 in) RED 60 mm (2.36 in) SOLENOID VALVE 3 4 5 1 2 3 4 5 at046a01.cgm 01A-080 CONNECTOR "B" WAY SOLENOID VALVE Installation of the Electrical Wiring Figure 7015/GRAPHIC 30-11-76-991-018-B01 30-11-76 Page 7054 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-420-804-B01 16. Installation of the Pressure Relief Valve and the Cover (01A-010) (Ref. IPL Fig. 01A) For PNR B03AA1060 and B03AA1060 Amdt A, B A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Tools, Fixtures and Equipment (a) Consumable Materials CODE REFERENCE DESIGNATION M07B PERMABOND F245 SEALING MATERIAL M14B PR1005L SEALING COMPOUND SEALING MATERIAL M04X LOCKWIRE DIA 0,5 MM (0.019 IN) SEALING MATERIAL (2) Referenced Information REFERENCE PAGE BLOCK DESIGNATION GRAPHIC-30-11-76-991-001-B01 1 FIGURE 2 GRAPHIC-30-11-76-991-024-B01 10000 IPL FIGURE 01A TASK-30-11-76-820-802-B01 8000 TABLE OF TIGHTENING TORQUES C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-420-009-B01 (1) Installation of the Pressure Relief Valve (a) Install the valve (01A-270), the spring (01A-260) and the cover (01A-240). (b) Apply locking material (M14B) on the three screws (01A-250). (c) Install the three screws (01A-250) and torque them to the specified value (Ref. TASK 30-11-76-820-802-B01). SUBTASK 30-11-76-420-010-B01 (2) Installation of the Cover (01A-010) (a) Apply sealing material (M14B) on the three screws (01A-020) and the two screws (01A-030). (b) Install the cover (01A-010) and attach it with the three screws (01A-020) and the two screws (01A-030). 30-11-76 Page 7055 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (c) Torque the screws to the specified value (Ref. TASK 30-11-76-820-802-B01). (d) Safety the two screws (01A-030) (Ref. Fig. 2 Sheet 1/2) with safety material (M04X). SUBTASK 30-11-76-410-003-A01 (3) Installation of the Identification Plate (01A-450) E. (a) Apply sealing material (M07B) on the identification plate (01A-450). (b) Install the identification plate (01A-450) on the cover (01A-010). Close-up Not applicable 30-11-76 Page 7056 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FITS AND CLEARANCES TASK 30-11-76-820-801-A01 1. Fits and Clearances A. DELETED 30-11-76 Page 8001 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-820-802-A01 2. Tightening Torques For PNR B03AA1040 and B03AA1040 Amdt A, B, C, D, E, F A. Table of Tightening Torques CAUTION: TIGHTEN TO THE RATED TORQUE TO GET A CORRECT TORQUE. THE TIGHTENING TORQUES IN THE TABLE BELOW ARE THE MINIMUM AND MAXIMUM RECOMMENDED VALUES. IPL FIG. AND ITEM No DESCRIPTION (01-020) TIGHTENING TORQUE daN.m and (lbf. in) Minimum Maximum SCREW 0,108 (9.56) 0,132 (11.68) (01-030) SCREW 0,108 (9.56) 0,132 (11.68) (01-050) SCREW 0,108 (9.56) 0,132 (11.68) (01-070) SCREW 0,108 (9.56) 0,132 (11.68) (01-090) SCREW 0,108 (9.56) 0,132 (11.68) (01-110) SCREW 0,072 (6.37) 0,087 (7.70) (01-130) SCREW 0,108 (9.56) 0,132 (11.68) (01-170) SCREW 0,072 (6.37) 0,087 (7.70) (01-180) SWITCH, PRESSURE 0,27 (23.90) 0,33 (29.21) (01-210) SCREW 0,135 (11.95) 0,165 (14.60) (01-230) SCREW 0,108 (9.56) 0,132 (11.68) (01-250) SCREW 0,108 (9.56) 0,132 (11.68) (01-290) SCREW 0,130 (11.51) 0,170 (15.05) (02-020) SCREW 0,108 (9.56) 0,132 (11.68) (02-050) SCREW 0,135 (11.95) 0,165 (14.60) (02-100) NUT 0,108 (9.56) 0,132 (11.68) (02-190) NUT 0,135 (11.95) 0,165 (14.60) (02-220) SCREW 0,108 (9.56) 0,132 (11.68) (02-225) SCREW 0,108 (9.56) 0,132 (11.68) (02-230B) NOZZLE 0,144 (12.74) 0,176 (15.58) 30-11-76 Page 8002 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-820-802-B01 3. Tightening Torques For PNR B03AA1060 and B03AA1060 Amdt A, B A. Table of Tightening Torques CAUTION: TIGHTEN TO THE RATED TORQUE TO GET A CORRECT TORQUE. THE TIGHTENING TORQUES IN THE TABLE BELOW ARE THE MINIMUM AND MAXIMUM RECOMMENDED VALUES. IPL FIG. AND ITEM No DESCRIPTION (01A-020) TIGHTENING TORQUE daN.m and (lbf. in) Minimum Maximum SCREW 0,108 (9.56) 0,132 (11.68) (01A-030) SCREW 0,108 (9.56) 0,132 (11.68) (01A-050) SCREW 0,108 (9.56) 0,132 (11.68) (01A-070) SCREW 0,108 (9.56) 0,132 (11.68) (01A-090) SCREW 0,108 (9.56) 0,132 (11.68) (01A-170) PLUG, THREADED 0,27 (23.90) 0,33 (29.21) (01A-210) SCREW 0,135 (11.95) 0,165 (14.60) (01A-230) SCREW 0,108 (9.56) 0,132 (11.68) (01A-250) SCREW 0,108 (9.56) 0,132 (11.68) (01A-290) SCREW 0,130 (11.51) 0,170 (15.05) (02A-020) SCREW 0,108 (9.56) 0,132 (11.68) (02A-050) SCREW 0,135 (11.95) 0,165 (14.60) (02A-100) NUT 0,108 (9.56) 0,132 (11.68) (02A-190) NUT 0,135 (11.95) 0,165 (14.60) (02A-220) SCREW 0,108 (9.56) 0,132 (11.68) (02A-225) SCREW 0,108 (9.56) 0,132 (11.68) (02A-230B) NOZZLE 0,144 (12.74) 0,176 (15.58) 30-11-76 Page 8003 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 8004 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES TASK 30-11-76-940-801-A01 1. Special Tool, Fixtures and Equipment A. Special Tool Table CODE QTY PART NUMBER DESCRIPTION USE T01 1 M65724395 SUPPORT To assemble the dual valves T02 1 OS22766 MOUNTING NOSE To install the preformed packing (01-190) T03 1 M82000232 TEST TOOL To test the solenoid valves T04 1 M65725780 WRENCH To remove and install the pressure switches (01-180) T05 1 M82000403 OR EQUIVALENT CONTROL BOX Functional test T06 1 SBE1333 COUPLING TOOL Functional test T07 2 M82000404 COUPLING TOOL Functional test T08 1 SBE1335 COUPLING TUBE Functional test T09 1 M82000189-1400 CABLE CIRCUIT A Functional test of the B03AA1040 series Used with (T05) T10 1 M82000189-1401 CABLE CIRCUIT B Functional test of the B03AA1040 series Used with (T05) T11 1 M82000189-1402 CABLE CIRCUIT A Functional test of the B03AA1060 series Used with (T05) T12 1 M82000189-1403 CABLE CIRCUIT B Functional test of the B03AA1060 series Used with (T05) T13 1 M65724517 CABLE CIRCUIT A To test the insulation resistance of the connector A T14 1 M65724518 CABLE CIRCUIT B To test the insulation resistance of the connector B T15 1 M65724509 CABLE CIRCUIT C To test the insulation resistance of the connector C 30-11-76 Page 9001 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series CODE QTY PART NUMBER DESCRIPTION USE T16 1 M65724519 CABLE CIRCUIT A To test the insulation resistance of the connector A T17 1 M65724520 CABLE CIRCUIT B To test the insulation resistance of the connector B 30-11-76 Page 9002 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series T01 at049a01.cgm T02 Special Tools Figure 9001/GRAPHIC 30-11-76-991-020-A01 30-11-76 Page 9003 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series T03 at050b01.cgm T04 Special Tools Figure 9002/GRAPHIC 30-11-76-991-021-A01 30-11-76 Page 9004 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series T05 at051a01.cgm T06 Special Tools Figure 9003/GRAPHIC 30-11-76-991-022-A01 30-11-76 Page 9005 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series T07 at052a01.cgm T08 Special Tools Figure 9004/GRAPHIC 30-11-76-991-023-A01 30-11-76 Page 9006 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series T09 T10 0 82 M 1 00 89 x xx -x T11 T12 0 82 M 1 00 89 at114a01.cgm x xx -x Special Tools Figure 9005/GRAPHIC 30-11-76-991-026-A01 30-11-76 Page 9007 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series T13 65 M 17 45 72 T14 65 M at171a01.cgm 18 45 72 Special Tools Figure 9006/GRAPHIC 30-11-76-991-031-A01 30-11-76 Page 9008 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series T15 65 M 09 45 72 T16 T17 65 M 19 45 72 65 M at172a01.cgm 20 45 72 Special Tools Figure 9007/GRAPHIC 30-11-76-991-032-A01 30-11-76 Page 9009 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-941-801-A01 2. Consumable Materials A. Consumable Materials Table NOTE: You can use equivalent alternatives for the items in the list. Code letter: A- Cleaning materials D- Coating material B- Adhesive materials, Locking materials Sealing materials E- Storage materials Packaging materials C- Lubricating materials X- Other materials DESIGNATION PART NUMBER AND SPECIFICATION MANUFACTURER OR SUPPLIER (NAME, ADDRESS AND CODE) CODE PAGE BLOCK WHERE USED DENATURED METHANOL USA (OM23214) OT(S.747) LOCAL VENDOR M09A 4001 TURCO 4181 TURCO FRANCE SA 3 IMP DU QUAI DE L’INDUSTRIE 91200 ATHIS-MONS F3172 FRANCE M48A 4001 70030 CARECLEAN AS1 CASTROL FRANCE SA 66 RTE DE SARTROUVILLE 78230 LEPECQ F3591 FRANCE M49A 4001 TURCO AVIATION SPR ATOFINA 4 CRS MICHELET LA DEFENSE 10 92800 PUTEAUX F7860 FRANCE M51A 4001 PROMOCLEAN TP 108 PROMOSOL SA BD HENRI CAHN 94360 BRY SUR MARNE F5927 FRANCE M53A 4001 CEMENT SILASTIC RTV732 DOW CORNING FRANCE SA M06B 300 RTE DES CRETES 06560 VALBONNE F7286 FRANCE 7001 30-11-76 Page 9010 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series DESIGNATION PART NUMBER AND SPECIFICATION MANUFACTURER OR SUPPLIER (NAME, ADDRESS AND CODE) CODE PAGE BLOCK WHERE USED PERMABOND F245 NATIONAL STARCH AND CHEMICAL (DIV PERMABOND) Z.I. NORD ARNAS 299 R. GRANGE MORIN 69655 ARNAS FRANCE SEALING COMPOUND PR1005L JOINT FRANCAIS (LE) (LJF) GROUPE HUTCHINSON 2 RUE BALZAC 75008 PARIS 8 F0229 FRANCE M14B 7001 RHODORSIL CAF730 RHODIA CHIMIE 26 QUAI ALPHONSE LE GALLO 92100 BOULOGNE BILLANCOURT F0107 FRANCE M50B 7001 GRAPHITE POWDER F F (AIR 4224) USA (SS-G-659A) ACHESON FRANCE SA BP 68 67152 ERSTEIN CEDEX F5606 FRANCE M01C 7001 GREASE MAGNALUBE G USA (MIL-G-23549) PIREP (PLASTIQUES INDUSTRIELS RECHERCHES ETUDES POLYTETRAFLUORETHYLENE) BP 119 62190 LILLERS FA814 FRANCE M05C 7001 CLEAR VARNISH LOCAL VENDOR M03D 15001 M04D 6001 ALODINE 1200 USA (MIL-C-5541A) CFPI INDUSTRIES SA 28 BD CAMELINAT 92230 GENNEVILLIERS F2865 FRANCE PACKING PAPER VALLUTHENE P21 CLASS 12 GRADE A TYPE C M01E RHODIA CHIMIE 25 QU PAUL DOUMER 92408 COURBEVOIE CEDEX F0107 FRANCE 15001 30-11-76 Page 9011 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series DESIGNATION PART NUMBER AND SPECIFICATION MANUFACTURER OR SUPPLIER (NAME, ADDRESS AND CODE) CODE PAGE BLOCK WHERE USED SHEET, TH.WELD. VALLUTHENE T SILVALAC (STE CLASS 1 & 2 INDUSTRIELLE DE LA VALLEE ET DES EMBALLAGES D’ARLAC) SA 7 R EUGENE FLACHAT 75017 PARIS F3689 FRANCE M02E 15001 STORAGE BAG WITH DESICCANT CECA SA USA (MIL-D-3464D) 4 A 8 CRS MICHELET 92800 PUTEAUX F3757 FRANCE M03E 15001 BULPACK TYPE GB8526 SHOCK ABSORBING MATERIAL SEALED AIR PACKAGING 53 RUE ST DENIS 28230 EPERNON F8307 FRANCE M04E 15001 WATERPROOF ABRASIVE PAPER PNR: M734C-P1200 3M FRANCE BD L’OISE 95006 CERGY PONTOISE CEDEX F0347 FRANCE M01X 6001 LOCKWIRE DIA. 0.5 MM (0.019 IN) INOX F (NFL23320) LOCAL VENDOR M04X 7001 FLUIDEL 5 NORMALE SN60PB DIA 10/10 METAUX BLANCS OUVRES ET MATIERES PLASTIQUES BP 49 21806 CHEVIGNY ST SAUVEUR CEDEX F3586 FRANCE M44X 7001 30-11-76 Page 9012 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series STORAGE (INCLUDING TRANSPORTATION) TASK 30-11-76-550-801-A01 1. Storage A. Reason for the Job Self-explanatory B. Job Set-up Information (1) Consumable Material CODE REFERENCE DESIGNATION M03D LOCAL VENDOR CLEAR VARNISH M01E VALLUTHENE P 21 CLASS 12 GRADE A TYPE C PAPER PACKING MATERIAL M02E TH.WELD. VALLUTHENE T CLASS 1& 2 SHEET M03E STORAGE BAG WITH DESICCANT STORAGE BAG M04E BULPACK TYPE GB 8526 SHOCK-ABSORBING MATERIAL C. Job Set-up Not applicable D. Procedure SUBTASK 30-11-76-530-001-A01 (1) Packaging (a) Make sure that all the projections and the sharp edges have a protection. Make sure that all the protective caps are installed on the component. (b) Put the component in the paper packing material (M01E). (c) Put the component in an envelope made of sheet (M02E), which has a minimum thickness of 0,2 mm (0.08 in). NOTE: When you seal the envelope, keep sufficient material so you can use the envelope three times. (d) Put the storage desiccant bags (M03E) along the length of the component, and safety them in position. (e) Put an identity label in the envelope, and make sure that you can read it when the envelope is closed. (f) Remove as much air as possible from the envelope. Heat-seal the envelope. NOTE: Do steps (c) to (f) quickly, because the storage bags are hygroscopic. 30-11-76 Page 15001 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series (g) Put the labels on the outer surface of the envelope. Write these three things on the labels: – “This envelope contains desiccant”. – “DO NOT OPEN until necessary for use”. – The date of packing. (h) Put the component in a cardboard box as written in ATA 300 - Class II. Fill the box with shock-absorbing material (M04E). (i) Close the container, and put a desiccant label on the outer surface of the container. (j) Apply clear varnish (M03D) on the labels. SUBTASK 30-11-76-550-001-A01 (2) Storage (a) Keep the component in a clean and dry room or building. The temperature must be between 18 °C and 22 °C (64 °F to 72 °F), and the relative humidity must be between 25% and 65%. (b) Keep the component in its initial box. Make sure that the stack in the store is not too high, to prevent damage. (c) Do not keep the component near corrosive fluids. (d) Put the package in a position which makes it easy to read the identification and humidity indicator labels. (e) Put the packaged component in the store in the sequence of its date. SUBTASK 30-11-76-550-002-A01 (3) Destorage (a) Remove the component from the box. (b) Collect the different trailer documents. (c) Remove the different storage parts. (d) Do a visual inspection of the component. SUBTASK 30-11-76-800-001-A01 (4) Transportation (a) E. Not applicable Close-up Not applicable 30-11-76 Page 15002 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series APPENDIX A TASK 30-11-76-800-801-A01 1. Acceptance Test Repair Data Sheet (ATRDS) A. Test Procedure NOTE: "ACTUAL VALUE A": Write this value before the repairs. "ACTUAL VALUE B": Write this value before the installation on the aircraft. APPLICABLE PAGES: A-1 TO A-4 FILE No: PNR: B03AA1040, B03AA1040 AMDT A, B, C, D, E, F S/N: TESTED BY: DATE: FINAL INSPECTION APPROVAL BY: DATE: POSITION IN THE CMM MEASUREMENT PAGE BLOCK 1000 NOMINAL VALUE ACTUAL ACTUAL TOLERANCE VALUE A VALUE B ELECTRICAL TEST ELECTRICAL CONTINUITY TEST SUBTASK 30-11-76-750- R between the bonding point of the plate (01-200) and: 001-A01 – The electrical connector (01-040) or ≤ 20 mΩ (01-060) or (01-080) – The pressure switches (01-180) (Remove ≤ 20 mΩ the cover (01-100) – The body (01-280) ≤ 20 mΩ – The Nozzle S/A (02-210) ≤ 20 mΩ ELECTRICAL CIRCUIT TEST SUBTASK 30-11-76-750- Resistance between pins A and B 002-A01 Connector A: R = 100 ± 10 Ω Connector B: R = 100 ± 10 Ω Connector C: R = 225 ± 22 Ω Insulation resistance test Pressure switch and solenoid valve for connector “A”: R Pressure switch and solenoid valve ≥ 100 MΩ ≥ 100 MΩ for connector “B”: R Re-heating: R ≥ 10 MΩ FUNCTIONAL TEST FUNCTIONAL TEST OF PRESSURE SWITCH 30-11-76 APPENDIX A Page A-1 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series APPLICABLE PAGES: A-1 TO A-4 FILE No: PNR: B03AA1040, B03AA1040 AMDT A, B, C, D, E, F S/N: TESTED BY: DATE: FINAL INSPECTION APPROVAL BY: DATE: POSITION IN THE CMM PAGE BLOCK 1000 MEASUREMENT SUBTASK 30-11-76-700- Pressure (P1): increased 001-A01 Solenoïd energized: 28 Vdc NOMINAL VALUE ACTUAL ACTUAL TOLERANCE VALUE A VALUE B Pilot lamp: OFF – Pressure switch A 1160 mbar rel. ≤ P ≤ 1240 mbar rel. (16.8 psig ≤ P ≤ 18 psig) – Pressure switch B 1160 mbar rel. ≤ P ≤ 1240 mbar rel. (16.8 psig ≤ P ≤ 18 psig) Pressure (P1): decreased to 0 bar (0 psi) Solenoïd energized: 28 Vdc Pilot lamp: ON – Pressure switch A P > 800 mbar rel. (11.6 psig) – Pressure switch B P > 800 mbar rel. (11.6 psig) FUNCTIONAL TEST SUBTASK 30-11-76-700- Pressure supply (P1): 1300 to 1320 mbar rel. 002-A01 (18.85 to 19.14 psig) Pressure supply time ≤ 30 s Solenoid A supply: 0 VDC Solenoid B supply: 0 VDC Circuit A outlet pressure (PA): ≤ - 70 mbar rel. (1.02 psig) Circuit B outlet pressure (PB): ≤ - 70 mbar rel. (1.02 psig) Pressure supply (P1): 1300 to 1320 mbar rel. (18.85 to 19.14 psig) Pressure supply time ≤ 5 s Solenoid A supply: 17 ± 1 VDC Solenoid B supply: 0 VDC Circuit “A” outlet (P1 - P2) ≤ 10 mbar (0.145 psi) Circuit B outlet pressure (PB): ≤ - 70 mbar rel. (1.02 psig) 30-11-76 APPENDIX A Page A-2 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series APPLICABLE PAGES: A-1 TO A-4 FILE No: PNR: B03AA1040, B03AA1040 AMDT A, B, C, D, E, F S/N: TESTED BY: DATE: FINAL INSPECTION APPROVAL BY: DATE: POSITION IN THE CMM PAGE BLOCK 1000 MEASUREMENT NOMINAL VALUE ACTUAL ACTUAL TOLERANCE VALUE A VALUE B Pressure supply (P1): 1300 to 1320 mbar rel. (18.85 to 19.14 psig) Pressure supply time ≤ 30 s Solenoid A supply: 0 VDC Solenoid B supply: 0 VDC Circuit A outlet pressure (PA): ≤ - 70 mbar rel. (1.02 psig) Circuit B outlet pressure (PB): ≤ - 70 mbar rel. (1.02 psig) Pressure supply (P1): 1300 to 1320 mbar rel. (18.85 to 19.14 psig) Pressure supply time ≤ 5 s Solenoid A supply: 0 VDC Solenoid B supply: 17 ± 1 VDC Circuit A outlet pressure (PA): ≤ - 70 mbar rel. (1.02 psig) Circuit “B” outlet pressure (P1 - PB) ≤ 10 mbar (0.145 psi) 30-11-76 APPENDIX A Page A-3 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 APPENDIX A Page A-4 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-800-801-B01 2. Acceptance Test Repair Data Sheet (ATRDS) A. Test Procedure NOTE: "ACTUAL VALUE A": Write this value before the repairs. "ACTUAL VALUE B": Write this value before the installation on the aircraft. APPLICABLE PAGES: A-5 TO A-6 FILE No: PNR: B03AA1060, B03AA1060 AMDT A, B S/N: TESTED BY: DATE: FINAL INSPECTION APPROVAL BY: DATE: POSITION IN THE CMM MEASUREMENT PAGE BLOCK 1000 NOMINAL VALUE ACTUAL ACTUAL TOLERANCE VALUE A VALUE B ELECTRICAL TEST ELECTRICAL CONTINUITY TEST SUBTASK 30-11-76-750- R between the bonding point of the 001-B01 plate (01A-200) and: – The electrical connector (01A-060) ≤ 20 mΩ or (01A-080) – The body (01A-280) ≤ 20 mΩ – The Nozzle S/A (02A-210) ≤ 20 mΩ ELECTRICAL CIRCUIT TEST SUBTASK 30-11-76-750- Resistance between pins 1 and 2 002-B01 Connector A: R = 100 ± 10 Ω Connector B: R = 100 ± 10 Ω Insulation resistance test Connector “A” solenoid valve: R ≥ 100 MΩ Connector “B” solenoid valve: R ≥ 100 MΩ FUNCTIONAL TEST FUNCTIONAL TEST SUBTASK 30-11-76-700- Pressure supply (P1): 1390 to 1410 mbar rel. 002-B01 (20.16 to 20.45 psig) Pressure supply time 30 s Solenoid A supply: 0 VDC Solenoid B supply: 0 VDC Circuit A outlet pressure (PA): ≤ - 70 mbar rel. (1.02 psig) 30-11-76 APPENDIX A Page A-5 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series APPLICABLE PAGES: A-5 TO A-6 FILE No: PNR: B03AA1060, B03AA1060 AMDT A, B S/N: TESTED BY: DATE: FINAL INSPECTION APPROVAL BY: DATE: POSITION IN THE CMM PAGE BLOCK 1000 MEASUREMENT Circuit B outlet pressure (PB): NOMINAL VALUE ACTUAL ACTUAL TOLERANCE VALUE A VALUE B ≤ - 70 mbar rel. (1.02 psig) Pressure supply (P1): 1390 to 1410 mbar rel. (20.16 to 20.45 psig) Pressure supply time 5 s Solenoid A supply: 17 ± 1 VDC Solenoid B supply: 0 VDC Circuit A outlet pressure (PA): = 1400 ± 10 mbar (20.16 to 20.45 psi) Circuit B outlet pressure (PB): ≤ - 70 mbar rel. (1.02 psig) Pressure supply (P1): 1390 to 1410 mbar rel. (20.16 to 20.45 psig) Pressure supply time 30 s Solenoid A supply: 0 VDC Solenoid B supply: 0 VDC Circuit A outlet pressure (PA): ≤ - 70 mbar rel. (1.02 psig) Circuit B outlet pressure (PB): ≤ - 70 mbar rel. (1.02 psig) Pressure supply (P1): 1390 to 1410 mbar rel. (20.16 to 20.45 psig) Pressure supply time 5 s Solenoid A supply: 0 VDC Solenoid B supply: 17 ± 1 VDC Circuit A outlet pressure (PA): ≤ - 70 mbar rel. (1.02 psig) Circuit B outlet pressure (PB): = 1400 ± 10 mbar (20.16 to 20.45 psi) 30-11-76 APPENDIX A Page A-6 Jun 01/06 COMPONENT MAINTENANCE MANUAL B03AA Series APPENDIX B TASK 30-11-76-880-801-A01 1. Approved Repairers A. List of Approved Repairers TRADE NAME LIEBHERR-AEROSPACE SALINE ADDRESS COMMENTS 1465 WOODLAND DR. SALINE MI 48176 U.S.A. Fax. (313) 429-2294 Tel. (313) 429-7225 LIEBHERR-AEROSPACE SINGAPORE N°. 8 PANDAM AVENUE 2260 SINGAPORE Fax. 65.265.2305 Tel. 65.265.2657 LIEBHERR-AEROSPACE TOULOUSE SAS 408, Avenue des Etats-Unis B.P. 52010 31016 TOULOUSE CEDEX FRANCE Tel. +33. (0)5.61.35.28.28 Fax. +33. (0)5.61.35.29.29 30-11-76 APPENDIX B Page B-1 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 APPENDIX B Page B-2 Sep 03/04 COMPONENT MAINTENANCE MANUAL B03AA Series ILLUSTRATED PARTS LIST 30-11-76 Page 10001 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 10002 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series TASK 30-11-76-871-802-A01 1. Introduction A. General The Illustrated Parts List (IPL) contains a list and the illustrations of the assemblies, and the detailed parts of the unit, in the disassembly sequence. It includes these sections: – – – – – – B. C. Introduction (INTRO) Optional Vendor Table (OVT) Vendors List (VL) Equipment Designator Index (EDI) Numerical Index (NI) Detailed Parts List (DPL). How to Use the Illustrated Parts List (1) You can find the illustration for a part, if you know the part number. Refer to the Numerical Index and look for the part number and the related figure and item number. Refer to the Detailed Parts List and look for the first figure and item number found in the Numerical Index for this part. It is possible that this figure shows the part in a section or a system of the component other than the one necessary. If it does, refer to the other figure numbers which are given in the Numerical Index. (2) To determine the part number of a given part, refer to the illustration which shows the assembly with this part. Record the item number of the illustrated part and refer to the Detailed Parts List, which gives its part number and its description. Vendors List (VL) The manufacturer codes have the capital letter "V" in front of them. These codes are used in the nomenclature of the Detailed Parts List to identify the source of procurement for the vendor items. A list of these codes and of the manufacturer’s names and addresses is given in the Vendors List. Where there is no code number, the full name of the manufacturer is included in the nomenclature column of the Detailed Parts List. D. Numerical Index (NI) (1) In this index, the part numbers are classified in this sequence: (a) The classification is made from the left to the right. Each digit (letter, numeral, dash) has its own meaning. (b) The sequence in the first left row is: (c) 1 An alpha letter A to Z (but not the "O" and the "I", because it is possible to read these letters as a zero and a one). 2 A numeral 0 to 9. For the subsequent rows, the sequence is: 1 A dash. 30-11-76 Page 10003 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (d) E. 2 An alpha letter A to Z (but not the "O" and the "I", because it is possible to read these letters as a zero and a one). 3 A numeral 0 to 9. The part number column contains all the part numbers which are included in the Detailed Parts List. The part numbers which are deleted or superseded in the Detailed Part List are listed in the Numerical Index, and they are identified as deleted or superseded. Detailed Parts List (DPL) (1) (2) Figure and Item Number (a) Each assembly, sub-assembly and part which has a part number, and which is given in the parts list, has an item number. (b) The figure number which is related to the item number is shown on the first line, at the top of each page. (c) Assemblies, the Sub-assemblies numbered parts which are in the list, but which are not illustrated, are identified with a dash (-) before the item number. (d) An index letter before the item number is cross-referenced to the figure which shows the modication of the part. Manufacturer’s Part Number A manufacturer’s part number is given to each assembly and to each detailed part, if it is illustrated and also if it is not illustrated. (3) Nomenclature (a) The nomenclature is given with an indenture, to show how the parts and the assemblies and related to their next higher assemblies. These are the details: 1 234 5 6 7 Assembly • Detailed parts for the assembly • Sub-assembly • Attaching parts and/or storage parts for the sub-assembly *** • • Detailed parts for the sub-assembly • • Sub-sub-assembly • • Attaching parts and/or storage parts for the sub-sub-assembly *** • • • Detailed parts for the sub-sub-assembly 30-11-76 Page 10004 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (4) (5) (6) (b) The attaching parts are shown immediately after the assembly of the part. In the list, they are below the same indenture number as the item they attach, and they are identified by the words "Attaching Parts". They are followed by three asterisks. (c) The manufacturer’s code, or the abbreviation NP (not procurable), is put at the end right-hand side of the first line of the nomenclature column on the right side. Effectivity Code (a) An alphanumerical index gives the effectivity of the sub-assemblies, and it gives the detailed parts list in relation to the next higher assembly(ies) or sub-assembly(ies). (b) When the effectivity is fully applicable, the use code column stays empty. (c) The use code for the assemblies, and the detailed parts list, refer to the figure/item number of the next higher assembly(ies) or sub-assembly(ies). Example: Effectivity 1A, 1B, 1C is written 1ABC. Units per Assembly (a) The units per assembly column shows the quantity of units necessary for one next higher assembly. (b) In some cases, the information is replaced by the abbreviation RF (for reference) or AR (as required). Abbreviations Used ALT FROM PNR XXX A part which is functionnally and physically interchangeable with the initial part after repair. AMDT Amendment. AR As required. DELETED Deleted part. DPL Detailed Parts List. EDI Equipment Designator Index. EFFECT CODE Effectivity code IPL Illustrated Parts List. LH Left-hand. MFR Manufacturer MODIFIED FROM A part got after a different part is modified. NHA Next higher assembly. NP Not procurable. Manufacturer or Optional Manufacturer in the DPL. 30-11-76 Page 10005 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series OPT PNR Optional part number Optional part number which is fully interchangeable with the part in the part number column. OPT SEE TABLE Refer to the optional table. F. ORDER OVERLGTH PNR A part number with more than fifteen characters. OVERSIZE A part with a size which is larger than its nominal dimension. PNR Part number. POST SB After a modification given up by a Service Bulletin. PRE SB Before a modification given up by a Service Bulletin. R Revised. RF For reference. RH Right hand. SEE CMM Refer to the Component Maintenance Manual. SEE FIG FOR DET Refer to the figure for details. SEE FIG FOR NHA Refer to the figure for the next higher assembly. SEL FROM Selected from. A part that you must select from a collection of parts, as necessary. SUPSD BY Superseded by xxx. SUPSDS Supersedes xxx. UNDERSIZE A part with a size which is smaller than its nominal dimension. UNITS PER ASSY Units Per Assembly VL Vendors List. Updating (1) General (a) When an item is revised, added or deleted, the letter "R" is shown in the right-hand margin (the date of issue changes). 30-11-76 Page 10006 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series (2) Added Items (a) (3) The basic sequence of the items are given in steps of 10. It is thus possible to add new items between the old ones, in the correct sequence of the breakdown. If you add more than nine new items, you must add new figure at the end of the IPL. New Figures Added (a) When new illustrations are necessary, the alternative figures are added. They refer to the same nomenclature. The alternative figure is given the basic figure number, with a letter. This letter is in front of the item number in the nomenclature. 30-11-76 Page 10007 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series VENDORS LIST CODE NAME ADDRESS VF0110 AFNOR (ASSOCIATION FRANCAISE DE NORMALISATION TOUR EUROPE 92049 PARIS LA DEFENSE CEDEX FRANCE VF0111 BNAE TECHNOPOLIS 54 199 RUE JEAN-JACQUES ROUSSEAU 92138 ISSY LES MOULINEAUX FRANCE VF0114 UTE (UNION TECHNIQUE DE L’ELECTRICITE ET DE LA COMMUNICATION) BP 23 92262 FONTENAY AUX ROSES CEDEX FRANCE VF0225 FCI FRANCE 145 R YVES LE COZ 78035 VERSAILLES FRANCE VF0331 SES STERLING SA BP 809 68308 ST LOUIS CEDEX FRANCE VF0344 PSM FIXATION BP 39 49241 AVRILLE CEDEX FRANCE VF0394 AMPHENOL - AIR LB 29 VOIE YVOIS 08110 BLAGNY FRANCE VF1868 DRAKA FILECA FOPTICA SA LIEUDIT LA PETITE CAMPAGNE RTE NATIONALE 1 60730 SAINTE GENEVIEVE FRANCE 30-11-76 Page 10008 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series CODE NAME ADDRESS VF1958 LIEBHERR-AEROSPACE TOULOUSE SAS 408 AV. DES ETATS-UNIS BP 52010 31016 TOULOUSE CEDEX FRANCE VF1983 CED (CONNECTEURS ELECTRIQUES DEUTSCH) (GROUPE COMPAGNIE DEUTSCH) DIVISION CONNECTEURS AEROMILITAIRES BP 117 27091 EVREUX CEDEX 9 FRANCE VF2521 PLASTIQUES DE FRANCE INDUSTRIES 845 AVE DU PIC DE BERTAGNE 13420 GEMENOS CEDEX FRANCE VF3341 HELLERMANNTYTON (CABLE MANAGEMENT PRODUCTS) GROUPE BOWTHORPE BP 130 78196 TRAPPES CEDEX FRANCE VF4482 VICTORIA TECHNOLOGIES ZI DE LA GARE 91690 GUILLERVAL FRANCE VF6220 RAYCHEM SA BP 8300 95802 CERGY PONTOISE CEDEX FRANCE VF9108 MOSS PIECES PLASTIQUES 1 RUE DU GUE 77990 LE MESNIL AMELOT FRANCE 30-11-76 Page 10009 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 10010 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series ALPHA/NUMERIC INDEX PART NUMBER FIGURE NUMBER ITEM NUMBER 01 380A 1 B03AA1010-0104 02 02A 150A 150A 2 2 B03AA1010-0105 02 02A 140A 140A 2 2 B03AA1010-048 02 090A 2 B03AA1010-049 02 02A 130A 130A 2 2 B03AA1010-050 02 110A 2 B03AA1010-063 02 02A 120A 120A 2 2 B03AA1010-098 02 02A 200A 200A 2 2 B03AA1012-018 01 180A 2 B03AA1020-020 01A 170A 2 B03AA1020-021 01A 095A 1 01 001A 001B 001C 001D 001E 001F 001G RF RF RF RF RF RF RF 02 02A 040A 040A 1 1 B03AA1040-0100 01 420A 1 B03AA1040-010A 02 02A 040B 040B 1 1 B03AA1040-011 02 02A 040C 040C 1 1 AFMJ11E22-04K B03AA1040 B03AA1040-010 AIRLINE STOCK NUMBER 30-11-76 TOTAL REQ’D Page 10011 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PART NUMBER FIGURE NUMBER ITEM NUMBER 01A 420A 1 B03AA1040-020 01 370A 2 B03AA1040-020A 01 370B 2 B03AA1040-021 01 370C 2 B03AA1040-030 01 01A 270A 270A 1 1 B03AA1040-040 02 02A 210A 210A 1 1 B03AA1040-048 02A 090A 2 B03AA1040-050 02 02A 180A 110A 180A 1 2 1 B03AA1040-060 02 02A 170A 170A 2 2 B03AA1040-070 01A 370A 2 B03AA1040-080 02 02A 340A 340A 1 1 B03AA1040-090 02 02A 210B 210B 1 1 01 150A 1 B03AA1040-10 02 02A 010A 010A 1 1 B03AA1040-11 01 01A 240A 240A 1 1 B03AA1040-13 01 01A 010A 010A 1 1 B03AA1040-14 02 02A 230A 230A 1 1 B03AA1040-16 01 180B 2 B03AA1040-0110 B03AA1040-1 AIRLINE STOCK NUMBER 30-11-76 TOTAL REQ’D Page 10012 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PART NUMBER FIGURE NUMBER ITEM NUMBER B03AA1040-17 01 02 140A 310A 2 2 B03AA1040-18 01 01A 200A 200A 1 1 B03AA1040-19 01A 040A 1 01 100A 1 B03AA1040-24 02 02A 230B 230B 1 1 B03AA1040-25 02 02A 240B 240B 1 1 B03AA1040-26 02 02A 260A 260A 1 1 B03AA1040-27 01 01A 430A 430A 1 1 B03AA1040-28 01 120A 1 B03AA1040-36 01 180C 2 B03AA1040-36A 01 180D 2 B03AA1040-5 01 01A 280A 280A 2 2 B03AA1040-6 01 01A 350A 350A 2 2 B03AA1040-7 01 01A 360A 360A 2 2 B03AA1040-8 01 01A 330A 330A 2 2 B03AA1040-9 02 02A 070A 070A 2 2 B03AA1060 01A 001A 001B 001C RF RF RF B03AA1040-2 AIRLINE STOCK NUMBER 30-11-76 TOTAL REQ’D Page 10013 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PART NUMBER FIGURE NUMBER ITEM NUMBER TOTAL REQ’D B03AANP76-01 01 02 440A 001A 1 RF B03AANP76-02 01 02 440B 001B 1 RF B03AANP76-03 01A 02A 440A 001A 1 RF B03AANP76-04 01A 02A 440B 001B 1 RF B03AANP76-05 01 02 440C 001C 1 RF B03AANP76-06 01A 02A 440C 001C 1 RF CTR1D1-4X3G 01 01A 300A 300A 4 4 F91CB1311-023 01 01A 320A 320A 2 2 H1Q1ZJ040028U 01 01A 290A 290A 4 4 HE302-2H083APN 01 040A 1 HE302-2H1006PN 01 060A 1 KZ05-06-9 01 400A AR LCB03AA1040-15 02 02A 240A 240A 1 1 N450PD100 02 02A 350A 350A 2 2 N450PD120 02 02A 360A 360A 1 1 01 380A 1 02 250A 1 PNR 001105-104-02 (optional, see basic P/N AFMJ11E22-04K) PNR 10-5X2-60C7 (optional, see basic P/N 10-5X2-50D6) AIRLINE STOCK NUMBER 30-11-76 Page 10014 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PART NUMBER FIGURE NUMBER ITEM NUMBER 02 250A 1 01A 070A 4 090A 4 01 01A 340A 340A AR AR 01 01A 340A 340A AR AR 02 02A 290A 290A 1 1 PNR 983-0SE10-05P6 (optional, see basic P/N 8533-0ES10-05P6) 01A 080A 1 PNR 983-0SE10-05PN (optional, see basic P/N 8533-0ES10-05PN) 01A 060A 1 PNR B03AA1040-010B (optional, see basic P/N B03AA1040-011) 02 040C 1 02A 040C 1 01 01A 240A 240A 1 1 01 120A 1 01 01A 415A 415A AR AR 01A 080A 1 PNR 10-5X2-61D6 (optional, see basic P/N 10-5X2-50D6) PNR 22294CF030014 (optional, see basic P/N 22293CA030014) PNR 23117CA016 (optional, see basic P/N 9090-48) PNR 23117UB016 (optional, see basic P/N 9090-48) PNR 5X1-50D5 (optional, see basic P/N 5X1-21A6) PNR B03AA1040-20 (optional, see basic P/N B03AA1040-11) PNR B03AA1040-3 (optional, see basic P/N B03AA1040-28) PNR L0H3 CORD LACING (optional, see basic P/N T18R) PNR S635-013 (optional, see basic P/N 8533-0ES10-05P6) AIRLINE STOCK NUMBER 30-11-76 TOTAL REQ’D Page 10015 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PART NUMBER FIGURE NUMBER ITEM NUMBER PNR S635-014 (optional, see basic P/N 8533-0ES10-05PN) 01A 060A 1 PNR S635-038 (optional, see basic P/N HE302-2H083APN) 01 040A 1 PNR S635-044 (optional, see basic P/N HE302-2H1006PN) 01 060A 1 PNR SR1002-10326 (optional, see basic P/N N450PD100) 02 350A 2 RNF100-3-32-0 01 410A AR S100-71 02 320A 2 S100-906 01 01A 260A 260A 1 1 S1240A 01 01A 450A 450A 1 1 01 080A 1 T18R 01 01A 415A 415A AR AR 10-5X2-50D6 02 02A 250A 250A 1 1 01 390A 16 15-386 02 02A 030A 030A 2 2 20X1-5-61D6 02 02A 300A 300A 1 1 22256CA040016 02 02A 050A 050A 8 8 22259CA030012 01 170A 2 22259CA040008 01 01A 210A 210A 5 5 S635-050 100-060-56 AIRLINE STOCK NUMBER 30-11-76 TOTAL REQ’D Page 10016 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PART NUMBER FIGURE NUMBER ITEM NUMBER 01 01A 230A 230A 1 1 22293CA025005 01 110A 4 22293CA030005 01 020A 130A 250A 020A 250A 3 1 3 3 3 22259CF030006E AIRLINE STOCK NUMBER 01A TOTAL REQ’D 22293CA030006 02 02A 020A 020A 1 1 22293CA030007 01 050A 070A 090A 050A 4 4 4 4 01A 22293CA030014 01A 070A 090A 4 4 22293CA030022 02 02A 225A 225A 1 1 22293CA030024 02 220A 220B 220A 220B 2 3 2 3 01 01A 030A 030A 2 2 01 160A 220A 220A 2 1 1 100A 190A 100A 190A 2 2 2 2 060A 060A 2 2 02A 22296CA030005 22541N030 01A 22541N040 02 02A 232531 02 02A 30-11-76 Page 10017 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series PART NUMBER AIRLINE STOCK NUMBER FIGURE NUMBER ITEM NUMBER TOTAL REQ’D 23320CA050 01 01A 02 02A 460A 460A 330A 330A AR AR AR AR 32X2-61D6 02 02A 080A 080A 2 2 4-47X1-78-61D6 02 02A 160A 160A 2 2 5X1-21A6 02 02A 290A 290A 1 1 8-9X1-9-21A6 01 01A 190A 190A 2 2 8533-0ES10-05P6 01A 080A 1 8533-0ES10-05PN 01A 060A 1 88003-12 01 01A 310A 310A AR AR 8X1-61D6 02 02A 270A 270A 1 1 9090-48 01 01A 340A 340A AR AR 9X1-61D6 02 02A 280A 280A 1 1 30-11-76 Page 10018 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series OPTIONAL VENDOR INDEX PART NUMBER OPTIONAL VENDOR’S CODE OPTIONAL PART NUMBER PART NUMBER VENDOR CODE 10-5X2-50D6 ZZZZZZ PNR 10-5X2-60C7 PNR 10-5X2-61D6 VF4482 VF4482 22293CA030014 ZZZZZZ PNR 22294CF030014 VF0111 5X1-21A6 ZZZZZZ PNR 5X1-50D5 VF4482 8533-0ES10-05P6 ZZZZZZ PNR 983-0SE10-05P6 PNR S635-013 VF1983 VF1958 8533-0ES10-05PN ZZZZZZ PNR 983-0SE10-05PN PNR S635-014 VF1983 VF1958 9090-48 ZZZZZZ PNR 23117CA016 PNR 23117UB016 VF0111 VF0111 AFMJ11E22-04K ZZZZZZ PNR 001105-104-02 VF0394 B03AA1040-011 ZZZZZZ PNR B03AA1040-010B VNP B03AA1040-11 ZZZZZZ PNR B03AA1040-20 VF1958 B03AA1040-28 ZZZZZZ PNR B03AA1040-3 VF1958 HE302-2H083APN ZZZZZZ PNR S635-038 VNP HE302-2H1006PN ZZZZZZ PNR S635-044 VNP N450PD100 ZZZZZZ PNR SR1002-10326 VF9108 T18R ZZZZZZ PNR L0H3 CORD LACING VF1868 30-11-76 Page 10019 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 10020 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series DETAILED PARTS LIST 30-11-76 Page 10021 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 430 300 40 50 280 290 310 370 330 250 240 320 340 300 350 70 60 410 360 80 90 260 420 270 10 440 30 380 415 200 390 20 220 210 150 230 420 160 130 100 170 180B 140 120 110 at009b01.cgm 190 Dual Distributor Valve Figure 01/GRAPHIC 30-11-76-991-024-A01 30-11-76 Page 10022 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 01 – 001A B03AA1040 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 RF VALVE, DUAL, DISTRIBUTOR NP PRE PRE PRE PRE – 001B B03AA1040 SB SB SB SB B03AA-30-04 B03AA-30-06 B03AA-30-07 B03AA-30-08 RF VALVE, DUAL, DISTRIBUTOR NP AMDT A, POST SB B03AA-30-04 PRE SB B03AA-30-05 PRE SB B03AA-30-06 PRE SB B03AA-30-07 PRE SB B03AA-30-08 – 001C B03AA1040 RF VALVE, DUAL, DISTRIBUTOR NP AMDT B, POST SB B03AA-30-05 PRE SB B03AA-30-06 PRE SB B03AA-30-07 PRE SB B03AA-30-08 – 001D B03AA1040 RF VALVE, DUAL, DISTRIBUTOR NP AMDT C, POST SB B03AA-30-06 PRE SB B03AA-30-07 PRE SB B03AA-30-08 – 001E B03AA1040 RF VALVE, DUAL, DISTRIBUTOR NP AMDT D, POST SB B03AA-30-07 PRE SB B03AA-30-08 PRE SB B03AA-30-09 – 001F B03AA1040 RF VALVE, DUAL, DISTRIBUTOR NP AMDT E, POST SB B03AA-30-08 PRE SB B03AA-30-09 – 001G B03AA1040 VALVE, DUAL, DISTRIBUTOR RF NP AMDT F, POST SB B03AA-30-09 010A B03AA1040-13 – . COVER 1 ITEM NOT ILLUSTRATED 30-11-76 Page 10023 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 01 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 ATTACHING PARTS 020A 22293CA030005 . SCREW 3 (VF0111) 030A 22296CA030005 . SCREW 2 (VF0111) *** 040A HE302-2H083APN 1 . CONNECTOR (VF0114) OPT TO PNR S635-038 MADE BY (NP) ATTACHING PARTS 050A 22293CA030007 . SCREW 4 (VF0111) *** 060A HE302-2H1006PN 1 . CONNECTOR (VF0114) OPT TO PNR S635-044 MADE BY (NP) ATTACHING PARTS 070A 22293CA030007 . SCREW 4 (VF0111) *** 080A S635-050 . CONNECTOR 1 ATTACHING PARTS 090A 22293CA030007 . SCREW 4 (VF0111) *** 100A B03AA1040-2 . COVER 1 ATTACHING PARTS 110A 22293CA025005 . SCREW 4 (VF0111) *** – ITEM NOT ILLUSTRATED 30-11-76 Page 10024 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 01 PART NUMBER 120A B03AA1040-28 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . PLATE OPT TO PNR B03AA1040-3 1 ATTACHING PARTS 130A 22293CA030005 . SCREW 1 (VF0111) *** 140A B03AA1040-17 . RESISTOR, HEATING 2 150A B03AA1040-1 . BODY 1 ATTACHING PARTS 160A 22541N030 . NUT 2 (VF0111) 170A 22259CA030012 . SCREW 2 (VF0111) *** – 180A B03AA1012-018 . SWITCH, PRESSURE 2 NP SUPSD BY 180B 180B B03AA1040-16 . SWITCH, PRESSURE PRE SB B03AA-30-08 SUPSDS 180A – 180C B03AA1040-36 1A, 1B, NP 1C, 1D, 1E 2 1F 2 1G 2 . SWITCH, PRESSURE NP POST SB B03AA-30-08 PRE SB B03AA-30-09 – 180D B03AA1040-36A 190A 8-9X1-9-21A6 . SWITCH, PRESSURE POST SB B03AA-30-09 . PACKING, PREFORMED 2 (VF4482) 200A B03AA1040-18 – . PLATE 1 ITEM NOT ILLUSTRATED 30-11-76 Page 10025 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 01 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 ATTACHING PARTS 210A 22259CA040008 . SCREW 5 (VF0111) *** 220A 22541N030 . NUT 1 (VF0111) 230A 22259CF030006E . SCREW 1 (VF0111) 240A B03AA1040-11 . COVER OPT TO PNR B03AA1040-20 1 ATTACHING PARTS 250A 22293CA030005 . SCREW 3 (VF0111) *** 260A S100-906 . SPRING 1 270A B03AA1040-030 . VALVE, PRESSURE, RELIEF 1 . BODY 2 – 280A B03AA1040-5 ATTACHING PARTS 290A H1Q1ZJ040028U . SCREW 4 (VF0110) *** 300A CTR1D1-4X3G . NAIL, KNURLED 4 (VF0344) – 310A 88003-12 . SHIM AR 320A F91CB1311-023 . SPRING 2 330A B03AA1040-8 . SHIM 2 340A 9090-48 . SHIM OPT TO PNR 23117UB016 MADE BY (VF0111) OPT TO PNR 23117CA016 MADE BY (VF0111) AR ITEM NOT ILLUSTRATED 30-11-76 Page 10026 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 01 PART NUMBER AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 350A B03AA1040-6 . CORE 2 360A B03AA1040-7 . DIAPHRAGM 2 – 370A B03AA1040-020 1A 2 1A, 1B, NP 1C, 1D 2 1E, 1F, NP 1G 2 . COIL NP PRE SB B03AA-30-04 SUPSD BY 370B 370B B03AA1040-020A . COIL POST SB B03AA-30-04 PRE SB B03AA-30-07 SUPSDS 370A – 370C B03AA1040-021 . COIL POST SB B03AA-30-07 380A AFMJ11E22-04K 1 . MODULE, JUNCTION (VF1983) OPT TO PNR 001105-104-02 MADE BY (VF0394) 390A 100-060-56 . CONTACT 16 (VF1983) – 400A KZ05-06-9 . WIRE, ELECTRICAL, WHITE AR (VF0114) USEFUL LENGTH 300MM 410A RNF100-3-32-0 . SLEEVE, HEAT, SHRINKABLE (VF6220) AR 415A T18R . CLAMP AR (VF3341) OPT TO PNR L0H3 CORD LACING MADE BY (VF1868) 420A B03AA1040-0100 . BRAID, BONDING 1 430A B03AA1040-27 . PLATE, BONDING 1 440A B03AANP76-01 . BODY, EQUIPPED, S/A 1A, 1B 1 1C 1 NP SEE FIG. 02-001A FOR DET – 440B B03AANP76-02 . BODY, EQUIPPED, S/A NP SEE FIG. 02-001B FOR DET – ITEM NOT ILLUSTRATED 30-11-76 Page 10027 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 01 – 440C B03AANP76-05 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . BODY, EQUIPPED, S/A 1D, 1E, NP 1F, 1G 1 SEE FIG. 02-001C FOR DET – 450A S1240A . PLATE, IDENTIFICATION 1 NP – 460A 23320CA050 . LOCKWIRE AR (VF0111) – ITEM NOT ILLUSTRATED 30-11-76 Page 10028 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 10029 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 430 300 40 50 280 290 310 370 330 250 240 320 340 300 350 70 360 60 95 80 90 260 420 270 415 10 440 30 20 190 170 200 220 210 at010b01.cgm 230 Dual Distributor Valve Figure 01A/GRAPHIC 30-11-76-991-024-B01 30-11-76 Page 10030 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 01A – 001A B03AA1060 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 RF VALVE, DUAL, DISTRIBUTOR NP PRE SB B03AA-30-05 PRE SB B03AA-30-06 – 001B B03AA1060 RF VALVE, DUAL, DISTRIBUTOR NP AMDT A POST SB B03AA-30-05 PRE SB B03AA-30-06 – 001C B03AA1060 RF VALVE, DUAL, DISTRIBUTOR NP AMDT B POST SB B03AA-30-06 010A B03AA1040-13 . COVER 1 ATTACHING PARTS 020A 22293CA030005 . SCREW 3 (VF0111) 030A 22296CA030005 . SCREW 2 (VF0111) *** 040A B03AA1040-19 . PLATE 1 ATTACHING PARTS 050A 22293CA030007 . SCREW 4 (VF0111) *** 060A 8533-0ES10-05PN . CONNECTOR 1 (VF0225) OPT TO PNR 983-0SE10-05PN MADE BY (VF1983) OPT TO PNR S635-014 – ITEM NOT ILLUSTRATED 30-11-76 Page 10031 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 01A AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 ATTACHING PARTS 070A 22293CA030014 4 . SCREW (VF0111) OPT TO PNR 22294CF030014 MADE BY (VF0111) *** 080A 8533-0ES10-05P6 1 . CONNECTOR (VF0225) OPT TO PNR 983-0SE10-05P6 MADE BY (VF1983) OPT TO PNR S635-013 ATTACHING PARTS 090A 22293CA030014 4 . SCREW (VF0111) OPT TO PNR 22294CF030014 MADE BY (VF0111) *** 095A B03AA1020-021 . SPACER 1 170A B03AA1020-020 . PLUG, THREADED 2 190A 8-9X1-9-21A6 . PACKING, PREFORMED 2 (VF4482) 200A B03AA1040-18 . PLATE 1 ATTACHING PARTS 210A 22259CA040008 . SCREW 5 (VF0111) *** 220A 22541N030 . NUT 1 (VF0111) 230A 22259CF030006E . SCREW 1 (VF0111) 240A B03AA1040-11 . COVER OPT TO PNR B03AA1040-20 250A 22293CA030005 . SCREW 1 3 (VF0111) – ITEM NOT ILLUSTRATED 30-11-76 Page 10032 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 01A PART NUMBER AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 260A S100-906 . SPRING 1 270A B03AA1040-030 . VALVE, PRESSURE, RELIEF 1 280A B03AA1040-5 . BODY 2 ATTACHING PARTS 290A H1Q1ZJ040028U . SCREW 4 (VF0110) *** 300A CTR1D1-4X3G . NAIL, KNURLED 4 (VF0344) 310A 88003-12 . SHIM AR 320A F91CB1311-023 . SPRING 2 330A B03AA1040-8 . SHIM 2 340A 9090-48 . SHIM OPT TO PNR 23117UB016 MADE BY (VF0111) OPT TO PNR 23117CA016 MADE BY (VF0111) 350A B03AA1040-6 . CORE 2 360A B03AA1040-7 . DIAPHRAGM 2 370A B03AA1040-070 . COIL 2 415A T18R . CLAMP AR AR (VF3341) OPT TO PNR L0H3 CORD LACING MADE BY (VF1868) 420A B03AA1040-0110 . BRAID, BONDING 1 430A B03AA1040-27 . PLATE, BONDING 1 440A B03AANP76-03 . BODY, EQUIPPED, S/A 1A 1 1B 1 NP SEE FIG. 02A-001A FOR DET – 440B B03AANP76-04 . BODY, EQUIPPED, S/A NP SEE FIG. 02A-001B FOR DET – ITEM NOT ILLUSTRATED 30-11-76 Page 10033 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 01A – 440C B03AANP76-06 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . BODY, EQUIPPED, S/A 1C 1 NP SEE FIG. 02A-001C FOR DET – 450A S1240A . PLATE, IDENTIFICATION 1 NP – 460A 23320CA050 . LOCKWIRE AR (VF0111) – ITEM NOT ILLUSTRATED 30-11-76 Page 10034 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 10035 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 260 220 225 310 210B 230B 240B 300 290 250 20 30 230 80 220B 90 320 110 310 270 280 240 210 10 70 100 300 290 120 140 130 180 150 190 160 60 170 340 200 40 360 350 50 at011b01.cgm 350 Equipped Body S/A Figure 02/GRAPHIC 30-11-76-991-025-A01 30-11-76 Page 10036 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 02 – 001A B03AANP76-01 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 BODY, EQUIPPED, S/A RF NP SEE FIG. 01-440A FOR NHA – 001B B03AANP76-02 BODY, EQUIPPED, S/A RF NP SEE FIG. 01-440B FOR NHA – 001C B03AANP76-05 BODY, EQUIPPED, S/A RF NP SEE FIG. 01-440C FOR NHA 010A B03AA1040-10 . PLATE 1 ATTACHING PARTS 020A 22293CA030006 . SCREW 1 (VF0111) *** 030A 15-386 . BLOCK, SILENT 2 (VF0331) 040A B03AA1040-010 . COVER PRE SB B03AA-30-05 1A 1 – 040B B03AA1040-010A . COVER POST SB B03AA-30-05 PRE SB B03AA-30-06 1B 1 – 040C B03AA1040-011 . COVER OPT TO PNR B03AA1040-010B MADE BY (NP) POST SB B03AA-30-06 1C 1 ATTACHING PARTS 050A 22256CA040016 . SCREW 8 (VF0111) *** 060A 232531 . SPRING 2 070A B03AA1040-9 . GUIDE 2 080A 32X2-61D6 . PACKING, PREFORMED 2 (VF4482) – ITEM NOT ILLUSTRATED 30-11-76 Page 10037 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 02 PART NUMBER 090A B03AA1010-048 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . FLANGE, LOWER 2 ATTACHING PARTS 100A 22541N040 . NUT 2 (VF0111) *** 110A B03AA1010-050 . VALVE 2 120A B03AA1010-063 . WASHER 2 130A B03AA1010-049 . FLANGE, UPPER 2 140A B03AA1010-0105 . SPACER 2 150A B03AA1010-0104 . WASHER 2 160A 4-47X1-78-61D6 . PACKING, PREFORMED 2 (VF4482) 170A B03AA1040-060 . VALVE, EQUIPPED 2 180A B03AA1040-050 . DIAPHRAGM, EQUIPPED 1 ATTACHING PARTS 190A 22541N040 . NUT 2 (VF0111) *** 200A B03AA1010-098 . AXLE 2 210A B03AA1040-040 . NOZZLE, S/A 1 NP USE UP SUPSD BY 210B 210B B03AA1040-090 . NOZZLE, S/A SUPSDS 210A 1 ATTACHING PARTS 220A 22293CA030024 . SCREW 210B 2 210A 3 (VF0111) 220B 22293CA030024 . SCREW (VF0111) – ITEM NOT ILLUSTRATED 30-11-76 Page 10038 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 02 PART NUMBER 225A 22293CA030022 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . SCREW 210B 1 (VF0111) *** 230A B03AA1040-14 . . NOZZLE 210A 1 230B B03AA1040-24 . . NOZZLE 210B 1 240A LCB03AA1040-15 . . INJECTOR 210A 1 240B B03AA1040-25 . . INJECTOR 210B 1 250A 10-5X2-50D6 . . PACKING, PREFORMED 210B 1 210B 1 210A 1 210A 1 (VF4482) OPT TO PNR 10-5X2-61D6 MADE BY (VF4482) OPT TO PNR 10-5X2-60C7 MADE BY (VF4482) 260A B03AA1040-26 . . BODY 270A 8X1-61D6 . . PACKING, PREFORMED (VF4482) 280A 9X1-61D6 . . PACKING, PREFORMED (VF4482) 290A 5X1-21A6 1 . PACKING, PREFORMED (VF4482) OPT TO PNR 5X1-50D5 MADE BY (VF4482) 300A 20X1-5-61D6 . PACKING, PREFORMED 1 (VF4482) 310A B03AA1040-17 . RESISTOR, HEATING 2 320A S100-71 . SPRING 2 – 330A 23320CA050 . LOCKWIRE AR (VF0111) 340A B03AA1040-080 . BODY 1 350A N450PD100 . PLUG, PROTECTIVE 2 (VF2521) OPT TO PNR SR1002-10326 MADE BY (VF9108) – ITEM NOT ILLUSTRATED 30-11-76 Page 10039 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 02 PART NUMBER 360A N450PD120 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . PLUG, PROTECTIVE 1 (VF2521) – ITEM NOT ILLUSTRATED 30-11-76 Page 10040 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 10041 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series 260 220 225 210B 230B 240B 300 290 250 20 30 220B 230 80 90 320 110 270 280 240 70 100 300 290 120 140 130 180 150 190 160 60 170 340 200 40 360 350 350 50 at012b01.cgm 10 210 Equipped Body S/A Figure 02A/GRAPHIC 30-11-76-991-025-B01 30-11-76 Page 10042 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM PART NUMBER 02A – 001A B03AANP76-03 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 BODY, EQUIPPED, S/A RF NP SEE FIG. 01A-440A FOR NHA – 001B B03AANP76-04 BODY, EQUIPPED, S/A RF NP SEE FIG. 01A-440B FOR NHA – 001C B03AANP76-06 BODY, EQUIPPED, S/A RF NP SEE FIG. 01A-440C FOR NHA 010A B03AA1040-10 . PLATE 1 ATTACHING PARTS 020A 22293CA030006 . SCREW 1 (VF0111) *** 030A 15-386 . BLOCK, SILENT 2 (VF0331) 040A B03AA1040-010 . COVER PRE SB B03AA-30-05 1A 1 – 040B B03AA1040-010A . COVER POST SB B03AA-30-05 PRE SB B03AA-30-06 1B 1 – 040C B03AA1040-011 . COVER OPT TO PNR B03AA1040-010B MADE BY (NP) POST SB B03AA-30-06 1C 1 ATTACHING PARTS 050A 22256CA040016 . SCREW 8 (VF0111) *** 060A 232531 . SPRING 2 070A B03AA1040-9 . GUIDE 2 080A 32X2-61D6 . PACKING, PREFORMED 2 (VF4482) – ITEM NOT ILLUSTRATED 30-11-76 Page 10043 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 02A PART NUMBER 090A B03AA1040-048 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . FLANGE, LOWER, S/A 2 ATTACHING PARTS 100A 22541N040 . NUT 2 (VF0111) *** 110A B03AA1040-050 . VALVE 2 120A B03AA1010-063 . WASHER 2 130A B03AA1010-049 . FLANGE, UPPER 2 140A B03AA1010-0105 . SPACER 2 150A B03AA1010-0104 . WASHER 2 160A 4-47X1-78-61D6 . PACKING, PREFORMED 2 (VF4482) 170A B03AA1040-060 . VALVE, EQUIPPED 2 180A B03AA1040-050 . DIAPHRAGM, EQUIPPED 1 ATTACHING PARTS 190A 22541N040 . NUT 2 (VF0111) *** 200A B03AA1010-098 . AXLE 2 210A B03AA1040-040 . NOZZLE, S/A 1 NP USE UP SUPSD BY 210B 210B B03AA1040-090 . NOZZLE, S/A SUPSDS 210A 1 ATTACHING PARTS 220A 22293CA030024 . SCREW 210B 2 210A 3 (VF0111) 220B 22293CA030024 . SCREW (VF0111) – ITEM NOT ILLUSTRATED 30-11-76 Page 10044 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series FIG. ITEM 02A PART NUMBER 225A 22293CA030022 AIRLINE STOCK NUMBER NOMENCLATURE EFFECT UNITS CODE PER ASSY 1234567 . SCREW 210B 1 (VF0111) *** 230A B03AA1040-14 . . NOZZLE 210A 1 230B B03AA1040-24 . . NOZZLE 210B 1 240A LCB03AA1040-15 . . INJECTOR 210A 1 240B B03AA1040-25 . . INJECTOR 210B 1 250A 10-5X2-50D6 . . PACKING, PREFORMED 210B 1 210B 1 210A 1 210A 1 (VF4482) 260A B03AA1040-26 . . BODY 270A 8X1-61D6 . . PACKING, PREFORMED (VF4482) 280A 9X1-61D6 . . PACKING, PREFORMED (VF4482) 290A 5X1-21A6 1 . PACKING, PREFORMED (VF4482) OPT TO PNR 5X1-50D5 MADE BY (VF4482) 300A 20X1-5-61D6 . PACKING, PREFORMED 1 (VF4482) – 330A 23320CA050 . LOCKWIRE AR (VF0111) 340A B03AA1040-080 . BODY 1 350A N450PD100 . PLUG, PROTECTIVE 2 (VF2521) 360A N450PD120 . PLUG, PROTECTIVE 1 (VF2521) – ITEM NOT ILLUSTRATED 30-11-76 Page 10045 Jul 01/07 COMPONENT MAINTENANCE MANUAL B03AA Series This page intentionally left blank. 30-11-76 Page 10046 Jul 01/07

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