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decrane aerospace 5000 Component Maintenance Manual With Illustrated Parts List

Track & swivel seats
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Component Maintenance Manual
with Illustrated Parts List for
© 2004 THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF DECRANE AIRCRAFT SEATING COMPANY,
INC., AND SHALL NOT BE REPRODUCED, USED, OR DISCLOSED TO OTHERS EXCEPT AS AUTHORIZED BY
CONTRACT WITH THE COMPANY, OR WITHOUT THE WRITTEN PERMISSION OF THE COMPANY.
Report: CMM 5001
Rev. B
Model 5000
Track & Swivel Seats
Prepared by:
Checked by:
Quality Review by:
Approved by:
25-20-02
George McKnight
Stephen Brown
Pamela J. Hough
Peter Dettmers
Cover
10/20/04

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Summary of Contents for decrane aerospace 5000

  • Page 1 Component Maintenance Manual with Illustrated Parts List for Model 5000 Track & Swivel Seats Prepared by: George McKnight Checked by: Stephen Brown Quality Review by: Pamela J. Hough Approved by: Peter Dettmers © 2004 THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF DECRANE AIRCRAFT SEATING COMPANY, INC., AND SHALL NOT BE REPRODUCED, USED, OR DISCLOSED TO OTHERS EXCEPT AS AUTHORIZED BY...
  • Page 5 LIST OF EFFECTIVE PAGES PAGE DATE PAGE DATE PAGE DATE Cover 10/20/04 10/20/04 1016 10/20/04 LEP 1 10/20/04 10/20/04 LEP 2 10/20/04 10/20/04 RR 1 10/20/04 10/20/04 RR 2 10/20/04 10/20/04 RTR 1 10/20/04 10/20/04 RTR 2 10/20/04 10/20/04 SBL 1 10/20/04 10/20/04 SBL 2...
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK 25-20-02 Report: CMM 5001 LEP-2 Rev. B 10/20/04...

  • Page 7: Record Of Revisions

    RECORD OF REVISIONS Revision Revision Date Summary of Changes Number Date Filed Added quality sign-off title page and corrected 01/25/02 01/25/02 typo’s 10/20/04 10/20/04 Updated company name and logo. (Replaced Dettmers Industries with DeCrane Aircraft Seating Company, Inc.) 25-20-02 Report: CMM 5001 RR 1 Rev.
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK 25-20-02 Report: CMM 5001 RR 2 Rev. B 10/20/04...

  • Page 9: Record Of Temporary Revisions

    RECORD OF TEMPORARY REVISIONS Temporary Page Date Issued Date Removed Inserted By Rev. No. Number Removed 25-20-02 Report: CMM 5001 RTR 1 Rev. B 10/20/04...
  • Page 10 THIS PAGE INTENTIONALLY LEFT BLANK 25-20-02 Report: CMM 5001 RTR 2 Rev. B 10/20/04...

  • Page 11: Service Bulletin List

    SERVICE BULLETIN LIST Service Issue Date Summary of Bulletin Bulletin Date Filed 25-20-02 Report: CMM 5001 SBL 1 Rev. B 10/20/04...
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  • Page 13: Table Of Contents

    TABLE OF CONTENTS List of Effective Pages..........................1 Record of Revisions ..........................1 Record of Temporary Revisions......................1 Service Bulletin List ..........................1 Table of Contents ...........................1 List of Figures............................3 List of Tables............................3 Description and Operation ........................1 General............................1 Description..........................1 Manual Seat Operation ......................2 Motorized Seat Operation ......................3 Seat Installation Requirements ....................4 Testing and Fault Isolation .......................101 General..........................101...
  • Page 14 Cleaning ............................401 General..........................401 Non-Upholstered Parts......................401 Fabric ............................401 Leather ..........................401 Check ..............................501 General..........................501 Structure..........................501 Operational Checks.......................501 Repair..............................601 General..........................601 Metal Surfaces ........................601 Upholstery Repairs........................601 Drop-down Armrest Mechanism ..................601 Track and Swivel Mechanism....................602 Cable Replacement and Adjustment..................602 Electrical Components ......................602 Assembly ............................701 General..........................701 Seat Track and Swivel Mechanism Installation..............701 Seatback Installation ......................701 Recline Cylinder Installation ....................701...
  • Page 15 LIST OF FIGURES Figure 1: Track & Swivel Seat........................1 Figure 1001: Parts Illustration ......................1002 Figure 1002: Seat Assembly Input Wiring – Single and Double Seats ..........1003 Figure 1003: Motor Wiring........................1004 Figure 1004: Potentiometer/Sensor Wires .................... 1005 Figure 1005: Connector C-2 Potentiometer Wires ................
  • Page 16 THIS PAGE INTENTIONALLY LEFT BLANK 25-20-02 Report: CMM-5001 TC 4 Rev. B 10/20/04...

  • Page 17: Description And Operation

    DESCRIPTION AND OPERATION General A. This Component Maintenance Manual (CMM) provides maintenance and operating instructions for the Model 5000 Track & Swivel Seats designed and manufactured by DeCrane Aircraft Seating Company, Inc. (DASC) (TSO previously held by Dettmers Industries). B. These seat designs have been tested and approved by the Federal Aviation Administration (FAA) to be identified by DASC as forward/rearward facing seats, meeting the requirements of TSO-C39b.

  • Page 18: Manual Seat Operation

    D. All seats have an Identification TSO placard located on the seat pan under the seat cushion. Should you need to contact DASC for answers to questions about a specific seat, it is important to obtain the part number and serial number from this placard before calling. Manual Seat Operation A.

  • Page 19: Motorized Seat Operation

    E. Recliner Footrest (if so equipped) The footrest can be moved to any position from a vertical to a horizontal position to support the occupant’s legs in an elevated position. To deploy the footrest, push the release pushbutton. When the desired position is reached, release the pushbutton.

  • Page 20: Seat Installation Requirements

    C. Lumbar, Seatback, Tilt, and Footrest Controls (DASC) Depressing the horizontal lumbar pushbuttons will move the lumbar support in or out Depressing the vertical lumbar pushbuttons will move the lumbar support up or down Depressing the seatback pushbuttons will raise or lower the seatback Depressing the tilt pushbuttons will move the seatback and pan up or down from the horizontal plane Depressing the footrest pushbuttons will raise or lower the footrest...
  • Page 21 C. Passenger seats must be arranged so that they are either forward or aft facing for takeoff and landing conditions. It is important to know the seat installation limitations are for takeoff and landing conditions. A placard will be installed at each seat, indicating the takeoff and landing position of the seat.
  • Page 22 THIS PAGE INTENTIONALLY LEFT BLANK 25-20-02 Report: CMM 5001 Page 6 Rev. B 10/20/04...

  • Page 23: Testing And Fault Isolation

    TESTING AND FAULT ISOLATION General A. This section contains test procedures to ensure that the seat operational mechanisms are installed and working properly. B. Unless otherwise specified, the tests should be performed with the seat weighted with a minimum of a 200 lbs (91 kg) passenger or equivalent. All controls and cabling must be installed to perform these tests.
  • Page 24 Pull up and hold the release lever (or depress the pushbutton) and move the seat to a different horizontal and rotational position. Release the lever (or pushbutton). Attempt to move and rotate the seat in any direction to check that the seat is locked in the desired position.
  • Page 25 F. Specialty Controls (if so equipped) Tilt Controls (a) Depress the tilt control pushbutton to tilt the seat fully back. Motion must be free and without binding. Release the pushbutton. (b) Try to pull seat forward. No evidence of slippage of seat. (c) Depress the tilt control pushbutton to tilt the seat in mid position and release the pushbutton.
  • Page 26 Slowly lower the headrest approximately halfway in (stopping at the nearest detent). Ensure headrest remains in position. Motion must be free and without binding and remains in position when released. Lower headrest until it stops. Headrest fully inserted without binding. H.

  • Page 27: Table 101: Restraint System Fault Isolation

    Fault Isolation A. Restraint System Table 101: Restraint System Fault Isolation Trouble Probable Cause Corrective Action Foreign object lodged in Remove foreign object. The lap belt does not catch mechanism. or release the belt tongue. Damaged belt mechanism. Replace mechanism. Foreign object lodged in Remove foreign object.

  • Page 28: Table 103: Seat Reclining Mechanism Fault Isolation

    Table 102: Track & Swivel Fault Isolation Trouble Probable Cause Corrective Action Damaged track & swivel Replace. assembly. The track & swivel assembly does not lock in Damaged lock release. Replace. the desired position. Damaged control cable. Replace. C. Seat Reclining Mechanism Table 103: Seat Reclining Mechanism Fault Isolation Trouble Probable Cause...

  • Page 29: Table 104: Lumbar Support Mechanism Fault Isolation

    Table 103: Seat Reclining Mechanism Fault Isolation Trouble Probable Cause Corrective Action Damaged recline lock. Replace. The seatback recline Damaged control cable. Replace. assembly does not lock in the desired position. Broken shock release Replace. spring. D. Lumbar Support (if so equipped) Table 104: Lumbar Support Mechanism Fault Isolation Trouble Probable Cause...

  • Page 30: Table 105: Tilt Mechanism Fault Isolation

    E. Tilt Mechanism (if so equipped) Table 105: Tilt Mechanism Fault Isolation Trouble Probable Cause Corrective Action Obstructed by a foreign Remove foreign object. object. The seat binds during its travel or does not move at Damaged control cable. Replace. all.

  • Page 31: Table 107: Takeoff & Landing Positioning Fault Isolation

    G. Motorized Takeoff & Landing Positioning (if so equipped) Table 107: Takeoff & Landing Positioning Fault Isolation Trouble Probable Cause Corrective Action Obstructed by a foreign Remove foreign object. object. The seat does not return to the correct takeoff & Damaged potentiometer.

  • Page 32: Table 110: Armrest Fault Isolation

    Table 109: Headrest Fault Isolation Trouble Probable Cause Corrective Action Damaged headrest tubing. Replace. The headrest will not stay Mal-adjusted or defective Refer to assembly in the desired position. detent screw(s). instructions to adjust detent screw(s). Replace if necessary. Armrest (if so equipped) Table 110: Armrest Fault Isolation Trouble Probable Cause...

  • Page 33: Table 111: Footrest Fault Isolation

    K. Footrest (if so equipped) Table 111: Footrest Fault Isolation Trouble Probable Cause Corrective Action A foreign object obstructs Remove foreign object. footrest mechanism. Damaged control cable. Replace. The footrest binds during Damaged or mal-adjusted Refer to assembly its travel. recline lock.
  • Page 34 B. CPU Enclosure Sub-Assembly CAUTION! The CPU Enclosure Sub-Assembly contains ESD sensitive electronic components. Improper handling may result in damage to the device that will reduce operational life Prior to “exposing” connector pins by removing aircraft cabling or ESD dissipative covers/caps/dummy plugs to service Seat, cabling, or the CPU Enclosure Sub- Assembly: Ensure that the Seat Frame is electrically bonded to aircraft frame ground.
  • Page 35 D. Seat Motion System Power Analysis, Wiring, and Circuit Protection General Notes Analysis covers Seat Motion System Only. PCU Supply, Under Seat Lighting, and In-Seat Monitor are not included. Power noted is “per-seat” Double Seat Assemblies are treated as two Seat Motion Systems.
  • Page 36 Single Seat Quiescent Power Consumption = 15.2W / 0.80 = 19.0W (at 120VAC/400Hz) (0.16A) Double Seat Quiescent Power Consumption (Assumption: both 28VDC to 5VDC power supplies and 28VDC to 7.6VDC power supplies are 80% efficient) (John Cyr enclosure measured at 28VDC, 0.14A = 4.0W. Factor of 1.2 included to adjust for “worst case”: 4.0W x 1.2 = 4.8W One John Cyr Enclosure .5W / 0.80...
  • Page 37 Wiring and Circuit Protection For the purpose of proper power wiring and protection, wire used for input power (120VAC/400Hz) should be #16 to #20 AWG, and should meet all applicable requirements for its intended use. Each seat should have separate wiring from a dedicated circuit breaker.
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  • Page 39: Disassembly

    DISASSEMBLY General NOTE See the section on Testing and Fault Isolation, to establish the condition of the component or most probable cause of its malfunction. This is to determine the extent of disassembly required without completely tearing down and rebuilding the component. CAUTION DO NOT disassemble the track &...

  • Page 40: Seat Pan Removal

    3. Seat Pan Removal A. Remove the seat cushion. B. Lower the seatback to the fully reclined position. C. Remove all screws from the seat pan. D. Cut all tie wraps, being careful not to cut any supported cabling. E. Remove the seat pan. 4.

  • Page 41: Recline Cylinder Removal

    Recline Cylinder Removal A. Remove the seat cushion. B. Ensure the seatback is in the full upright position. C. Remove the lock nut and bolt from the cylinder piston end. Support the shaft while removing the bolt to relieve the shaft tension. D.

  • Page 42: Headrest Removal

    11. Headrest Removal A. The headrest is easily removed by pulling it upward until the headrest shafts exit the guide tubes in the seatback. 12. Seat Track and Swivel Mechanism Removal CAUTION DO NOT disassemble the track & swivel mechanism. This assembly is preset at the factory to specified tolerances.
  • Page 43 C. If the CPU Enclosure Sub-Assembly must be removed from the seat frame or the Seat electrically detached from the aircraft frame ground, the CPU Enclosure Sub-Assembly MUST be maintained in an ESD-safe environment. It must not be placed upon a non- conductive surface such as carpeting or upholstery.
  • Page 44 THIS PAGE INTENTIONALLY LEFT BLANK 25-20-02 Report: CMM 5001 Page 306 Rev. B 10/20/04...
  • Page 45 CLEANING General A. Regular cleaning of all seats is necessary to maintain the cleanliness and preserve the appearance of the finish upholstery. B. All of the seat covering materials are specially treated for flame resistance to comply with 14 CFR 25.853(a) and (c), Amendment 25-83 dated 3/95. Therefore, in order to avoid damage to the protective finishes, the use of cleaning agents stronger than those specified is not recommended.

  • Page 46: Table 401: Cleaning Materials

    NOTE Equivalent items can be used after appropriate tests to ensure that the substitute materials do not damage the area being cleaned. Table 401: Cleaning Materials Nomenclature Part or Specification Source Number Federal Specification Commercially Available Aliphatic Naphtha TT-N-95 Brush, stiff-bristle, nonmetallic Federal Specification Commercially Available H-B-1490...
  • Page 47 CHECK General NOTE Excessive wear is defined as obvious deformation or deterioration of a part which can render that part inoperative. If doubt exists as to the serviceability of a part, replace the part. A. Visually check all parts for nicks, cracks, cuts, corrosion, crossed and stripped threads, scores, excessive wear, and other defects that could impair seat operation or safety.
  • Page 48 Adjustable Headrest per Step 2.D, page 102. Drop-down Armrest per Step 2.H, page 104. Recliner Footrest per Step 2.I, page 104. B. If any of the checks fail to satisfy the bolded criteria of the applicable operational test, troubleshoot, using Testing and Fault Isolation Step 3 (beginning on page 105) as a guide, and repair per the Section on Repair (beginning on page 601).
  • Page 49 REPAIR General A. Repair is limited to standard shop practices. Except for the permissible repairs outlined in this chapter, repair of parts and components are to be avoided since improper disassembly and assembly could compromise the safety-integrity of the seat assembly. B.
  • Page 50 A. Flat Spring Replacement Remove the screws to replace the spring. B. Lock Body Replacement Remove the screws to replace the lock body. C. Lock Rod Roll Pin Replacement Remove the roll pin. In case of breakage, replace with a stainless steel role pin. Track and Swivel Mechanism CAUTION DO NOT...
  • Page 51 ASSEMBLY General A. This section contains reassembly instructions in the reverse sequence of the IPL. Skip unnecessary steps if the seat assembly is already partially assembled. B. Damaged fasteners, e.g., screws, nuts, washers, etc., should be replaced rather than reused. Whenever possible, replace low-cost wear items during reassembly to prevent possible future maintenance due to failure.
  • Page 52 Footrest Cylinder Installation A. Attach the cylinder end to the support barrel, by turning the cylinder in a clockwise direction. Leave approximately 1/8-inch between the support barrel and the cylinder end. B. Pull the cylinder shaft until the shaft bracket holes align with the footrest bracket and install the bolt and lock nut.
  • Page 53 B. Align the screw holes with the mounting holes in the frame. C. Fasten seat pan to the seat frame with sheet metal screws. If the upholstered seatback is already installed, lower the seatback to the fully reclined position to facilitate installation of the sheet metal screws along the back of the seat.
  • Page 54 All assemblers/technicians that may or will touch the CPU Enclosure Sub-Assembly must wear an ESD-safe wrist or ankle strap. Integrity of the wrist/ankle strap must be tested prior to handling the CPU Enclosure Sub-Assembly. The CPU Enclosure Sub-Assembly may then be removed from an ESD dissipative container or bag and installed in the Seat Frame.
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  • Page 57: Special Tools, Fixtures And Equipment

    SPECIAL TOOLS, FIXTURES AND EQUIPMENT Special Tools A. Magnetic 16-inch No. 2 Phillips screwdriver or equivalent. 2. Fixtures and Equipment A. None 25-20-02 Report: CMM 5001 Page 901 Rev. B 10/20/04...
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  • Page 59: Illustrated Parts List

    A. This IPL contains information for identification and procurement of replaceable spare parts for the Model 5000 Track & Swivel seats designed and manufactured by DASC Industries. B. All component assemblies, subassemblies, and detail parts that are considered to be replaceable for reasons of wear, age, or damage are included in the IPL.

  • Page 60: Figure 1001: Parts Illustration

    PART NUMBER AIRLINE DESCRIPTION UNITS STOCK CODE NUMBER 1 2 3 4 5 ASSY Fig. 1001 5000-( ) Track & Swivel Chair UL32-040SP1 Hydrolock - recline UL32-090SP1 Hydrolock – footrest MC6424-00 Cable Assy – Lateral Brake MC-24-23 Cable Assy – recline MC-21-30 Cable Assy –...

  • Page 61: Figure 1002: Seat Assembly Input Wiring - Single And Double Seats

    Figure 1002: Seat Assembly Input Wiring – Single and Double Seats 25-20-02 Report: CMM 5001 Page 1003 Rev. B 10/20/04...

  • Page 62: Figure 1003: Motor Wiring

    Figure 1003: Motor Wiring 25-20-02 Report: CMM 5001 Page 1004 Rev. B 10/20/04...

  • Page 63: Figure 1004: Potentiometer/Sensor Wires

    Figure 1004: Potentiometer/Sensor Wires 25-20-02 Report: CMM 5001 Page 1005 Rev. B 10/20/04...

  • Page 64: Figure 1005: Connector C-2 Potentiometer Wires

    Figure 1005: Connector C-2 Potentiometer Wires 25-20-02 Report: CMM 5001 Page 1006 Rev. B 10/20/04...

  • Page 65: Figure 1006: Connector C-3 Motor Wires In Seat Back

    Figure 1006: Connector C-3 Motor Wires In Seat Back 25-20-02 Report: CMM 5001 Page 1007 Rev. B 10/20/04...

  • Page 66: Figure 1007: Connector C-4 Potentiometer Wires In Seat Back

    Figure 1007: Connector C-4 Potentiometer Wires In Seat Back 25-20-02 Report: CMM 5001 Page 1008 Rev. B 10/20/04...

  • Page 67: Figure 1008: Connector C-5 Input Power

    Figure 1008: Connector C-5 Input Power 25-20-02 Report: CMM 5001 Page 1009 Rev. B 10/20/04...

  • Page 68: Figure 1009: Connector C-7 28 Vdc Cpu Power Input

    Figure 1009: Connector C-7 28 VDC CPU Power Input 25-20-02 Report: CMM 5001 Page 1010 Rev. B 10/20/04...

  • Page 69: Figure 1010: Connector C-9 Network Output Option

    Figure 1010: Connector C-9 Network Output Option 25-20-02 Report: CMM 5001 Page 1011 Rev. B 10/20/04...

  • Page 70: Figure 1011: Connector C-10 Discrete Safety Switch Option

    Figure 1011: Connector C-10 Discrete Safety Switch Option 25-20-02 Report: CMM 5001 Page 1012 Rev. B 10/20/04...

  • Page 71: Figure 1012: Connector C-11 Arm Switch

    Figure 1012: Connector C-11 Arm Switch 25-20-02 Report: CMM 5001 Page 1013 Rev. B 10/20/04...

  • Page 72: Figure 1013: Motor Wiring Harness

    Figure 1013: Motor Wiring Harness 25-20-02 Report: CMM 5001 Page 1014 Rev. B 10/20/04...

  • Page 73: Figure 1014: Potentiometer Wiring Harness

    Figure 1014: Potentiometer Wiring Harness 25-20-02 Report: CMM 5001 Page 1015 Rev. B 10/20/04...