component maintenance manual with illustrated …

32890---------------------airbus-kid-page-start

COMPONENT MAINTENANCE MANUALWITH

ILLUSTRATED PARTS LIST

Panel Light

8400-1

COMPONENT MAINTENANCE MANUAL

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Initial Issue:

JUN 15/2005 33-34-01 Jun 15/2005

Copyright © 2005 Luminescent Systems Inc.

The information contained in this document is Luminescent Systems

Inc. proprietary information. It is disclosed in confidence and is

intended for internal use only by Luminescent Systems Inc.

authorized owner/lessee operators and repair stations. It is the

property of Luminescent Systems Inc. and shall not be altered,

reused, disclosed to others or reproduced for distribution or

redistribution in any form, paper or electronic, without the express

written consent of Luminescent Systems Inc. This includes but is not

limited to its use in the creation, manufacture, development, or

derivation of any repairs, modifications, spare parts, design, or

configuration changes or to obtain FAA or any other government or

regulatory approval to do so. If consent is given for reproduction in

whole or part, this notice shall appear in any such reproduction in

whole. Luminescent Systems Inc. assumes no liability whatsoever,

whether contractual, warranty, tort or otherwise, for unauthorized

alteration or alterations not performed in accordance with

Luminescent Systems Inc. approved procedures.


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RECORD OF REVISIONS

00 JUN 15/2005


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NO.

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DATE BY

RE.

NO.

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DATE

INSERTED

DATE BY

Retain this record in the front of the manual.

On receipt of revisions, insert revised page in the manual and enter

revision number, date and initials.

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SERVICE BULLETIN LIST


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DATE BY

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SUBJECT PAGE DATE

TITLE PAGE

TITLE 1 Jun 15/2005

TITLE 2 Jun 15/2005

RECORD OF REVISIONS

ROR 1 Jun 15/2005

ROR 2 blank

RECORD OF TEMPORARY REVISIONS

ROTR 1 Jun 15/2005

ROTR 2 blank

SERVICE BULLETIN LIST

SBL 1 Jun 15/2005

SBL 2 blank

LIST OF EFFECTIVE PAGES

LEP 1 Jun 15/2005

LEP 2 Jun 15/2005

TABLE OF CONTENTS

TOC 1 Jun 15/2005

TOC 2 Jun 15/2005

INTRODUCTION

INTRO 1 Jun 15/2005

INTRO 2 Jun 15/2005

DESCRIPTION AND OPERATION

1 Jun 15/2005

2 Jun 15/2005

SUBJECT PAGE DATE

TESTING AND FAULT ISOLATION

1001 Jun 15/2005

1002 Jun 15/2005

SCHEMATICS AND WIRING DIAGRAMS

2001 Jun 15/2005

2002 blank

DISASSEMBLY

3001 Jun 15/2005

3002 blank

CLEANING

4001 Jun 15/2005

4002 Jun 15/2005

CHECK

5001 Jun 15/2005

5002 blank

REPAIR

6001 Jun 15/2005

6002 blank

ASSEMBLY

7001 Jun 15/2005

7002 blank

FITS AND CLEARANCES

8001 Jun 15/2005

8002 blank


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PAGE 1

Jun 15/2005

SUBJECT PAGE DATE

SPECIAL TOOLS, FIXTURES,

EQUIPMENT AND CONSUMABLES

9001 Jun 15/2005

9002 blank


IPL-TP 10001 Jun 15/2005

IPL-TP 10002 blank

INTRODUCTION

INTRO 10001 Jun 15/2005

INTRO 10002 Jun 15/2005

INTRO 10003 Jun 15/2005

INTRO 10004 blank

NUMERICAL INDEX

NI 10001 Jun 15/2005

NI 10002 blank

DETAILED PARTS LIST

DPL 10001 Jun 15/2005

FIGURE 1: PANEL LIGHT

10001 - 0 Jun 15/2005

10001 - 1 Jun 15/2005

10001 - 2 blank

SPECIAL PROCEDURES

11001 Jun 15/2005

11002 blank

REMOVAL

12001 Jun 15/2005

12002 blank

SUBJECT PAGE DATE

INSTALLATION

13001 Jun 15/2005

13002 blank

SERVICING

14001 Jun 15/2005

14002 blank

STORAGE INCLUDING

TRANSPORTATION

15001 Jun 15/2005

15002 blank

REWORK

16001 Jun 15/2005

16002 blank


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TABLE OF CONTENTS

INTRODUCTION .............................................. INTRO 1

1. GENERAL ............................................. INTRO 1

2. PRODUCT SUPPORT ..................................... INTRO 1

3. MANUAL LAYOUT ....................................... INTRO 1

4. REVISION SERVICE .................................... INTRO 1

5. SHOP VERIFICATION ................................... INTRO 2

6. WARNINGS, CAUTIONS, NOTES ........................... INTRO 2

7. LIST OF ABBREVIATIONS ............................... INTRO 2

DESCRIPTION AND OPERATION ...................................... 1

1. GENERAL .................................................. 1

2. DESCRIPTION AND OPERATION ................................ 1

TESTING AND FAULT ISOLATION ................................. 1001

1. GENERAL ............................................... 1001

2. PREPARATION FOR THE TEST .............................. 1001

3. TESTING ............................................... 1002

A. TEST PROCEDURE .................................... 1002

SCHEMATICS AND WIRING DIAGRAMS .............................. 2001

1. GENERAL ............................................... 2001

2. SCHEMATICS AND WIRINGS ................................ 2001

DISASSEMBLY ................................................. 3001

CLEANING .................................................... 4001

1. GENERAL ............................................... 4001

2. LIST OF MATERIALS ..................................... 4001

3. PROCEDURE ............................................. 4001

CHECK ....................................................... 5001

1. GENERAL ............................................... 5001

2. LIST OF EQUIPMENT ..................................... 5001

3. PROCEDURE ............................................. 5001


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Jun 15/2005

REPAIR ...................................................... 6001

ASSEMBLY .................................................... 7001

FITS AND CLEARANCES ......................................... 8001

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES .......... 9001

1. LIST OF MATERIALS ..................................... 9001

ILLUSTRATED PARTS LIST ............................... IPL-TP 10001

INTRODUCTION ....................................... INTRO 10001

1. IPL INTRODUCTION ............................ INTRO 10001

2. LIST OF VENDORS ............................. INTRO 10003

NUMERICAL INDEX ....................................... NI 10001

DETAILED PARTS LIST .................................. DPL 10001

FIGURE 1: PANEL LIGHT ................................ 10001

SPECIAL PROCEDURES ......................................... 11001

REMOVAL .................................................... 12001

INSTALLATION ............................................... 13001

SERVICING .................................................. 14001

STORAGE INCLUDING TRANSPORTATION ........................... 15001

1. GENERAL .............................................. 15001

2. PROCEDURE ............................................ 15001

REWORK ..................................................... 16001


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Jun 15/2005

INTRODUCTION

TASK 33-34-01-99F-801-A1

1. GENERAL

This manual has been written in accordance with the ATA

iSpec2200. It includes the maintenance and repair instructions

of the unit.

TASK 33-34-01-99F-802-A1

2. PRODUCT SUPPORT

The Panel Light is product supported by:

Luminescent Systems Inc.

4 Lucent Drive

Lebanon, NH 03766-1439

USA

CAGE: 32890

Tel: 603-643-7766

Fax: 603-643-5947

E-mail: [email protected]

TASK 33-34-01-99F-803-A1

3. MANUAL LAYOUT

You will find the sections that follow in this manual:

– Description and Operation

– Testing and Fault Isolation

– Wiring Diagrams

– Disassembly

– Cleaning

– Check

– Repair

– Assembly

– Fits and Clearances

– Special Tools, Fixtures and Equipment

– Illustrated Parts List

– Special Procedures

– Removal

– Installation

– Servicing

– Storage (incl. Transportation)

– Rework

TASK 33-34-01-99F-804-A1

4. REVISION SERVICE

This manual will be changed as necessary by revisions because of

Service Bulletins for example.


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Jun 15/2005

TASK 33-34-01-99F-805-A1

5. SHOP VERIFICATION

The sections within this manual are approved. The applicable

tasks of disassembly, testing and assembly were done at

Luminescent Systems Inc.

TASK 33-34-01-99F-806-A1

6. WARNINGS, CAUTIONS, NOTES

A. WARNING

Warnings give instructions to the use of materials,

processes, methods, procedures or limits. Obey the

instructions accurately, if not, this can cause injury or

death of persons.

B. CAUTION

Cautions give instructions to the use of materials,

processes, methods, procedures or limits. Obey the

instructions accurately, if not, this can cause damage to

the equipment.

C. NOTE

Notes give instructions which make the job easier.

7. LIST OF ABBREVIATIONS

A AMPERE

A/C AIRCRAFT

ATA AIR TRANSPORT ASSOCIATION OF AMERICA

C CELSIUS

DC DIRECT CURRENT

hPa HECTO PASCAL

in. INCH

IPL ILLUSTRATED PARTS LIST

lb. POUND

mA MILLIAMPERE

mm MILLIMETER

R REVISED

RF REFERENCE

VDC VOLT DIRECT CURRENT


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33-34-01INTRO

PAGE 2

Jun 15/2005

DESCRIPTION AND OPERATION

TASK 33-34-01-870-806-A1

1. GENERAL

The Panel Light is part of the lighting system of the A/C. Refer

to (FIGURE 1) for a view of the Panel Light.

3289

0_C

3334

01_D

OP

01_R

00.c

gm

PANEL LIGHT

FIGURE 1

TASK 33-34-01-870-810-A1

2. DESCRIPTION AND OPERATION

A. Description

(1) The Panel Light is connected to the 28 VDC power

supply.

(2) The LEDs are a permanent part of the light assembly and

are not replacable.

(3) The Panel Light housing is made of aluminium.

(4) Refer to Table 1 for the technical data of the Panel

Light.


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Jun 15/2005

Dimensions Height: 25.4 mm (1.00 in.)

Width: 79.5 mm (3.13 in.)

Depth: 34.4 mm (1.35 in.)

Weight max. 60 g (0.13 lb)

Operating Voltage 28 VDC

Operating Current < 107 mA

Cable length incl.

Connector

132.5 +/- 6.4 mm (5.22 +/-

0.25 in.)

TECHNICAL DATA

TABLE 1

B. Operation

(1) Electrical Operation

(a) Connect the Panel Light to the 28 VDC power supply

to operate it.

(b) The maximum current is less than 107 mA.


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Jun 15/2005

TESTING AND FAULT ISOLATION

TASK 33-34-01-700-811-A1

1. GENERAL

A. This section gives procedures for testing the Panel Light.

B. Unit testing is required if a unit is received from the line

maintenance personnel with no definite fault localization

or after unit repair.

C. For internal wiring and pin designation of the unit refer to

(FIGURE 2001).

TASK 33-34-01-700-812-A1

2. PREPARATION FOR THE TEST

A. Test Conditions

Carry out testing and fault isolation at ambient room

conditions:

Temperature 18 to 28 °C (64.4 to 77 °F)

Atmospheric Pressure 880 to 1080 hPa

Relative Humidity 20 to 90 %

TEST CONDITIONS

TABLE 1001

B. Test Equipment and Materials

Description Source

Power Supply (5 - 30 VDC, +/-

1 %, Imax = 1 A)

Locally Available

DC Voltmeter (0 - 50 VDC, +/-

1 %)

Locally Available

Ohmmeter (20 mΩ - 10 MΩ, 10%)

Locally Available

Amperemeter (0 - 200 mA DC) Locally Available

TEST EQUIPMENT AND MATERIALS

TABLE 1002


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Jun 15/2005

TASK 33-34-01-700-813-A1

3. TESTING

SUBTASK 33-34-01-700-111-A1

A. TEST PROCEDURE

For the electrical test procedure refer to Table 1003.

Step/Procedure Set Value Required Value

1. Bonding Resistance

Perform a bonding

resistance test.

Measure the

resistance between:

– J1.C and the

metallic housing.

R </= 20 mΩ

2. Current Supply

Apply the supply

voltage between J1.A

(28 VDC) and J1.B (DC

RETURN).

28 VDC

Measure the supply

current.

< 107 mA

3. Functional Test

Apply the supply

voltage between J1.A

(28 VDC) and J1.B (DC

RETURN).

28 VDC Make sure that the

Panel Light

operates

correctly.

TEST PROCEDURE

TABLE 1003


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Jun 15/2005

SCHEMATICS AND WIRING DIAGRAMS

TASK 33-34-01-99F-821-A

1. GENERAL

This section contains schematics and wiring diagrams for the

unit.

TASK 33-34-01-990-821-A

2. SCHEMATICS AND WIRINGS

For internal wiring and pin designation of the unit refer to

(FIGURE 2001).

3289

0_C

3334

01_W

SD

01_R

00.c

gm

28 VDC

GND BND

DC RETURN

A

C

B

J1

PR

OT

EC

TIO

NC

IRC

UIT

PANEL LIGHT 8400-1

FIGURE 2001


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CLEANING

TASK 33-34-01-100-841-A1

1. GENERAL

This section gives procedures to clean the unit.

TASK 33-34-01-94A-841-A

2. LIST OF MATERIALS

The following materials are used in this section.

NOTE: Equivalent substitutes may be used for listed items.

ITEM SUPPLIER'S CODE

APRON LOCALLY AVAILABLE

GLOVES LOCALLY AVAILABLE

GOGGLES LOCALLY AVAILABLE

ISOPROPYL ALCOHOL LOCALLY AVAILABLE

LINT-FREE CLOTH LOCALLY AVAILABLE

MASK LOCALLY AVAILABLE

NON METALLIC BRUSH LOCALLY AVAILABLE

SOFT-BRISTLED BRUSH LOCALLY AVAILABLE

LIST OF MATERIALS

TABLE 4001

TASK 33-34-01-100-843-A1

3. PROCEDURE

WARNING: DO NOT BREATH IN VAPOR AND FUMES OF ISOPROPYL ALCOHOL.

WARNING: USE ISOPROPYL ALCOHOL UNDER A VENTILATED HOOD. WEAR A

SUITABLE MASK WHEN NECESSARY.

WARNING: AVOID CONTINUOUS CONTACT WITH ISOPROPYL ALCOHOL. USE

GOGGLES, GLOVES AND AN APRON TO PREVENT IRRITATION


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Jun 15/2005

FROM PROLONGED CONTACT. CHANGE CLOTHING UPON WHICH

ISOPROPYL ALCOHOL HAS BEEN SPILLED.

WARNING: ISOPROPYL ALCOHOL IS FLAMMABLE. OBSERVE ALL FIRE

PRECAUTIONS FOR FLAMMABLE MATERIALS AND OBEY THE

MANUFACTURERS' PRECAUTIONS.

WARNING: WARN OTHER PERSONS TO KEEP AWAY FROM HAZARDOUS AREA

WORKING ENCLOSURE.

A. Metal Parts

(1) Remove surface grease with a lint-free cloth.

(2) Blow dust from surfaces, holes and recesses with air

jet.

(3) Clean casing with isopropyl alcohol. Work isopropyl

alcohol over surfaces and into holes and recesses with

non metallic brush.

(4) Rinse casing with isopropyl alcohol. Position casing so

that isopropyl alcohol is not trapped in holes or

recesses and drain until dry. If positioning will not

permit complete draining, use air jet to blow out

trapped isopropyl alcohol.

(5) Protect casing from dust and moisture.

B. Non-Metal Parts

(1) Use a lint-free cloth soaked with mild soap and water

solution or equivalents and clean away dirt and grime

from the surfaces of the unit.

(2) Remove residues of sealing compound and adhesives from

non-metal parts and make sure that the surfaces are

clean.

(3) Dry the parts with a clean lint-free cloth.

C. Connectors

(1) CAUTION: DO NOT USE METAL TOOLS TO REMOVE FOREIGN

MATTER FROM THE SOCKETS OF THE CONNECTORS.

DAMAGE TO CONTACT PLATING CAUSES CORROSION.

Wipe dust and dirt from bodies with a lint-free cloth

moistened with isopropyl alcohol.

(2) Clean sockets with a small, soft-bristled brush

moistened with isopropyl alcohol.

(3) Wipe dry with a clean, dry, lint-free cloth and dry by

air jet.


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CHECK

TASK 33-34-01-210-851-A1

1. GENERAL

This section gives procedures to check the unit for damages.

TASK 33-34-01-210-852-A1

2. LIST OF EQUIPMENT

Equipment Source

Strong Light Locally Available

CHECK EQUIPMENT

TABLE 5001

TASK 33-34-01-210-853-A1

3. PROCEDURE

A. General Check

(1) Check the configuration and identification of the unit.

(2) Check the weight of the unit.

(3) Check all components and parts with a strong light for

the following:

– Breakage, dirt accumulation, grease, loose wiring or

foreign materials, sharp edges and burrs

– Corrosion, dents, chipped or scraped painted surfaces

and other evidences of physical damage

– Legible identification markings

– Proper mounting and alignment of detail parts

B. Metal Parts

Inspect metal parts for corrosion, dents, chipped or

scraped painted surfaces and other evidences of physical

damage such as broken or loose connectors, worn or defective

wiring and damaged parts.

C. Connectors

Inspect connectors for dirty or corroded contacts, bent or

broken pins and other physical damage.

D. Wiring

Check wiring for loose or poor connections and insulation

for burned, worn and broken areas.


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SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES

TASK 33-34-01-94A-891-A

1. LIST OF MATERIALS

The listed consumables are required to maintain the component.

NOTE: Equivalent substitutes may be used for listed items.

ITEM SUPPLIER'S CODE USE

C

L

E

APRON LOCALLY AVAILABLE X

GLOVES LOCALLY AVAILABLE X

GOGGLES LOCALLY AVAILABLE X

ISOPROPYL ALCOHOL LOCALLY AVAILABLE X

LINT-FREE CLOTH LOCALLY AVAILABLE X

MASK LOCALLY AVAILABLE X

NON METALLIC BRUSH LOCALLY AVAILABLE X

SOFT-BRISTLED BRUSH LOCALLY AVAILABLE X

LIST OF MATERIALS

TABLE 9001


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INTRODUCTION

TASK 33-34-01-99F-901-A1

1. IPL INTRODUCTION

A. General Information

This ILLUSTRATED PARTS LIST (IPL) contains all replaceable

parts of the Panel Light.

B. Organization

(1) The IPL has the following sections:

(a) Introduction

The introduction gives the basic data that is

necessary to use the IPL.

(b) List of Vendors

The List of Vendors (LOV) lists the manufacturer

codes, the names and the addresses.

(c) Numerical Index

This section lists part numbers in alphanumerical

sequence with reference to the figure and item

numbers and units per assy.

The structure of the part numbers is as follows

(from the left side to the right side):

- A through Z (without ’O’ as zero)

- 0 to 9

For subsequent rows, the order is:

- a dash

- A through Z (without ’O’ as zero)

- 0 to 9

(d) Detailed Parts List

1 Column ”FIG. / ITEM”

The first number in the first line of a page

shows the number of the figure that shows the

part. The second number shows the item number

by which the part is identified on the

illustration. A dash in front of the item

number shows that the part is not illustrated.


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2 Column ”PART NUMBER”

The part number column has the original

manufacturers’ part numbers. When standard

part numbers are used, the standard part

number is listed in this column.

3 Column ”AIRLINE STOCK NO.”

This column is blank for airline internal use.

4 Column ”NOMENCLATURE”

a Assembly Sequence Indenture

The names of the parts in the

Nomenclature column of the IPL are

indented to show which parts are

installed in other parts. The level of

indenture is shown by the number of dots

at the left edge of the Nomenclature

column. For example, the top assembly for

a parts list figure is at the left margin.

The names of its parts and subassemblies

are indented by one dot. Subsequent

subassemblies and parts are indented with

more dots.

b Attaching Parts

Attaching parts are written ATTACHING

PARTS and are listed immediately after

the parts which they attach. The ***

symbol follows the last item of the

attaching parts group.

c Vendor Codes

Parts made by companies other than

Luminescent Systems Inc. are identified

by an applicable vendor code after the

nomenclature.

Vendor codes are written with current

issues of U.S. Federal Supply Codes for

Manufacturer Handbooks H4-1, H4-2 and

H4-3 and have the letter ’V’.

5 Column ”EFF CODE”

The effectivity column shows parts connections

to units or assemblies which are almost the

same but have small differences. These units

or assemblies have reference letters such as

1A, 1B, 1C, etc.


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Parts which are not the same in all

configurations but are related to one or more

of the next higher assy, are identified with

the letter or letters of the top item.

When a component is part of all top items, the

effectivity column is blank.

6 Column ”UNITS PER ASSY”

This column contains the quantity of a part

required in the sequence of only one next

higher assembly. For items with variable

quantities, the letters ’AR’ are put in the

quantity column to show ’As Required’. When

items are recorded for reference purposes,

they are identified with ’RF’.

C. How to use the IPL

(1) If the part number is known

(a) Find the part number in the numerical index and

record the figure and the item number.

(b) Turn to the figure.

(c) Find the part on the illustration and in the parts

list by the item number.

(2) If the part number is unknown

(a) Refer to Figure 1 and find the figure item number

of the part.

(b) Record the figure item number.

(c) Turn to the figure parts list and find the related

part number.

2. LIST OF VENDORS

MFR VENDOR ADDRESS

32890 LUMINESCENT SYSTEMS INC.

4 LUCENT DRIVE

LEBANON, NH 03766-1439

USA

LIST OF VENDORS

TABLE 10001


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NUMERICAL INDEX

PART NUMBERAIRLINE

STOCK NUMBERFIG. ITEM

TTL

REQ

8400-1 1 1 RF


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DETAILED PARTS LIST


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3289

0_C

3334

01_I

PL0

1_R

00.c

gm

1

PANEL LIGHT

FIGURE 1


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FIG.

ITEMPART NUMBER

AIRL.

STOCK

NO.

NOMENCLATURE

1234567

EFF

CODEUPA

1

- 1 8400-1 LIGHT, PANEL RF


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SPECIAL PROCEDURES

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REMOVAL

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INSTALLATION

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SERVICING

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STORAGE INCLUDING TRANSPORTATION

TASK 33-34-01-550-951-A1

1. GENERAL

A. This section gives instructions for the storage of the unit.

B. Before storage, the unit should be thoroughly cleaned as

described in Cleaning.

C. Ensure that any parts which are not installed before storage

of the unit, such as attachment parts are clearly identified

in plastic bags and stowed together with the unit.

TASK 33-34-01-550-952-A1

2. PROCEDURE

A. Do not stack the unit.

B. Keep the unit in a clean room which has good ventilation, at

a temperature between 10 and 21 °C (50 and 70 °F) and ahumidity level of not more than 65 %.

C. Store the unit in its original packaging.

D. Do not store the unit near to corrosive fluids, heat, or

ozone generating sources.

E. Place the unit in a position which allows the identification

label to be easily read.

F. After the unit has been in storage for 1 year:

Inspect the unit and its component parts for damage.


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REWORK

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component maintenance manual with illustrated …

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