ROGERSON KRATOS

Pasadena, California

POTABLE WATER
QUANTITY INDICATOR

PART NOs. 115.115, 115.115-1,

115.115-3 and 115.115-4

COMPONENT MAINTENANCE MANUAL

WITH

ILLUSTRATED PARTS LIST

THE CONTENT OF THIS PUBLICATION IS THE PROPERTY OF, AND CONTAINS INFORMATION PROPRIETARY TO ROGERSON
AIRCRAFT CORPORATION. IN ORDER TO MINIMIZE THE POSSIBILITY OF OBSOLETE DATA BEING USED FOR MAINTENANCE.
OVERHAUL, AND REPAIR OF OUR EQUIPMENT, IT IS MADE AVAILABLE FOR THE EXCLUSIVE USE OF OWNERIOPERATORS OF
APPLICABLE AIRCRAFT. THIS MANUAL MAY NOT BE REPRODUCED IN WHOLE OR PART, NOR DISTRIBUTED TO OTHERS,
WITHOUT EXPLICIT WRITTEN PERMISSION FROM ROGERSON AIRCRAFT CORPORATION.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

RECORD OF REVISIONS

REVISION DATE DATE REVISION DATE DATE

NUMBER ISSUED FILED BY NUMBER ISSUED FILED BY

Rev 1 12-30-83
Rev 2 4-15-85
Rev 3 8-15-00

date issued
Retain this record in front ofthe manual. On receipt of revision, insert revised pages in the manual and enter revision number,
date filed and initials.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

RECORD OF TEMPORARY REVISIONS

TEMPORARY
REVISION PAGE DATE INSERTED DATE REMOVED
NUMBER NUMBER ISSUED BY REMOVED BY

tempormy revision number,

Retain this record in firon of the manual. On receipt of a temporazy revision, insert revised page in the manual and enter
page number, date issued, initial, or date removed and initial.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

SERVICE BULLETIN LIST

SERVICE DATE
BULLETIN DATE INCORPORATED/ INSERTED
NUMBER ISSUED SUPERCEDES BY

115.115-38-02 4-15-85

Retain this record in front of the manual. On receipt of a service bulletin, insert service bulletin number, date issued and initials.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115
LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE

Title Page T-1 Aug 15/00
Record of Revisions RR-1 Aug 15/00
Rec. of Temp. Rev's TR-1 Aug 15/00
Service Bulletin List SB-1 Aug 15/00
List of Effective Pgs. LEP-1 Aug 15/00
Table of Contents TC-1 Aug 15/00
Introduction INTRO-1 Aug 15/00
INTRO-2 Aug 15/00
Description and 1 Aug 15/00
Operation 2 Aug 15/00
Testing and 101 Aug 15/00
Equipment 102 Aug 15/00
Fault Isolation 103 Aug 15/00
104 Aug 15/00
Disassembly 301 Aug 15/00
302 Aug 15/00
Cleaning 401 Aug 15/00
402 Aug 15/00
Check 501 Aug 15/00
502 Aug 15/00
Repair 601 Aug 15/00
602 Aug 15/00
603 Aug 15/00
Assembly 701 Aug 15/00
702 Aug 15/00
703 Aug 15/00
704 Aug 15/00
705 Aug 15/00
Special Tools, Fixtures 901 Aug 15/00
and Equipment 902 Aug 15/00
Illustrated Parts List 1001 Aug 15/00
1002 Aug 15/00
1003 Aug 15/00
1004 Aug 15/00
1005 Aug 15/00
1006 Aug 15/00
1007 Aug 15/00
1008 Aug 15/00

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

TABLE OF CONTENTS

TITLE PAGE

Introduction......................................................... INTRO-I

Description and Operation ................. 1.........................

Testing and Fault Isolation............................................................................................ 101

Disassemblyv....................................................................................................................... 301

Cleaning ......................................................... 401

Check ........................................................... 501

Repair ........................................................... 601

Assembly ......................................................... 701

Special Tools, Fixtures and Equipment .................................... 901

Illustrated Parts List ................................................. 1001

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

INTRODUCTION

A. General

This manual can be used to perform maintenance and repairs on Potable Water Quantity
Indicator, part number 115.115 after the unit has been removed from the aircraft. The
Testing and Fault Isolation, Disassembly, Repair and Assembly sections are written so
that malfunctions can be determined and the affected component removed, repaired and
replaced.

B. Manufacturin2

The Potable Water Quantity Indicator Unit is manufactured by:

ROGERSON KRATOS PHONE: (626) 449-3090

430 South Raymond Avenue FAX: (626) 795-0322
Pasadena, California 91109 USA

C. Manual Layout

This technical manual consists of ten (10) topic sections which include the following:

Introduction
Description
Testing and Fault Isolation
Disassembly
Cleaning
Check
Repair
Assembly
Fits and Clearances (Only as they pertain)
Special Tools, Fixtures and Equipment
Illustrated Parts List

Refer to the Table of Contents for the page location of applicable procedure sections.
An explanation of the use of the Illustrated Parts List is provided in the beginning of
that topic section.

All weights and measurements are in English units and S.I. metric equivalent values
in parentheses

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

D. Revision Service

This manual will be revised as necessary to reflect current information. Service

Bulletins will be issued separately and as required to provide current configuration
information.

E. Shot Verification

This manual has been shop validated to the 115.115 configuration, as noted in the
following:

SECTION DATE

Testing 6/2/81
Disassembly 6/2/81
Assembly 6/2/81

F. List of Abbreviations

AR As Required
ASSY Assembly
co Celsius Degree
CU Cubic
DIA Diameter
DVM Digital Voltmeter
EFF Effectivity
F0 Fahrenheit Degree
FIG (Fig.) Figure
IN. (in.) Inch
LB. (lb.) Pound
MAX Maximum
MIN Minimum
MM (nun) Millimeter
NM (Nm) Newton-Meter
NHA Next Higher Assembly
NO Number
Oz Ounce
PN Part Number
RF Reference
V Volts
W Watt(s)

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

DESCRIPTION AND OPERATION

A. Water Ouantitv Indicator Description (Fieure 1)

as "the
Potable Water Quantity Indicator, Part Number 115.115, (hereafter referred to
the
Indicator), is a self-contained unit used to display the amount of potable water aboard
board assembly (CBA)
aircraft. Each indicator consists of a meter movement and a circuit of
mounted on a common frame and enclosed in a cylindrical case. The indicator consists
source
internal lamps to illuminate the meter face. The indicator is connected to a remote
in the potable water tanks/
with the
Four versions of the Potable Water Quantity Indicators are practically identical
same dial
exception of the dial indication displayed. PINs 115.115 and 115.115-3 have the
parameters. P/Ns 115-1 and 115.115-4 have the same dial parameters.

B. Operation

The indicator receives 0 to +I OVdc signal input power at pins 4 (+) and 3 (-) of connector
lights
(Figure 6). Pad resistors RI and R2 facilitate indicator calibration. Indicator dial
at pins I (+) and 2 (-) at
DS 1, DS2, and DS3 are activated by 5Vac aircraft input power
the connector.

115.115 115.115-1
115.115-3 115-4

Potable Water Quantity Indicator PIN 115.115

Figure 1

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

C. Leading Particulars

The leading particulars are listed in Table 1 as follows:

Signal Input Oto 10 Vdc
Insulation Resistance 20 Megohms min. at 500 Vdc; lighting ckt 100 Meg-
ohms min. at 500 Vdc.
Dielectric Strength 1000 Vrms, 60 Hz
Meter Accuracy:
115.115 (115.115-3) ± 2.4 gallons
115.115-1 (115.115-4) ± 3.2 gallons
Dial Movement 250 degrees taut band
Operating Altitude -1000 to +45,000 ft (-305 to 13,716 meters)
Operating Temperature -50F to +165 0F (-150C to +740 C)
Dimensions
Length 3.72 in. max (excluding connector)(94.5 mm max)
Diameter 1.57 in. (39.8 mm) max
Weight 6.9 oz. max (195 grams max)
Lighting Power 5 Vac aircraft interior power
Leading Particulars
Table 1

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

TESTING AND FAULT ISOLATION

A. Test Equipment

(1) No special tools, fixtures or equipment is required to conduct the testing in

this section. The standard shop tools required for testing are listed in
Table 101, called out in the appropriate test, and listed in the SPECIAL
TOOLS. FIXTURES AND EQUIPMENT section, along with their sources.

NOTE: Equivalent substitutes may be used for listed items.

Equipment Manufacturer Range

DC Power Supply Commercially Available 0 to 50 Vdc +0.01%
DC Calibrator John Fluke Mfg. Co. Inc., WA 0 to 20 Vdc
Resistance Decade Box (2 req.) Commercially Available 0 to 1K ohm
Test Equipment Requirement
Table 101

B. Functional Testin2

(1) Lamp Test

(a) Connect DC power supply topi 1 (+) and 2 (-) of the indicator being
tested.

(b) Apply 2.7 Vdc and verify that the indicator illumination shows uniform
dial and pointer brightness per BAC specification D6T 10783-1 or
equivalent parameters.

(c) Shut off power and disconnect power supply.

(2) Static Balance Test

(a) Rotate indicator 90 degrees in all directions from normally-mounted
position.
(b) Ensure that full deflection of pointer is less than 1%of full scale.

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PART NO. 115.115

(3) PerformanceTest(P/N 115.115 and 115.115-3)

(a) Connect indicator UUT to DC Calibrator from pins 4 (+) and 3 (-) of
UUT connector P 1. Allow for sufficient UUT and test equipment
warmup time.

(b) Verify that the calibrator is set to zero. Raise the calibrator voltage until
the meter reads 120 gallons. Apply calibrator voltages as shown in Table
102 and very that meter indication agrees (within tolerances) with those
listed.

(c) Shut off power and disconnect DC Calibrator from indicator T.

Meter Indication Nominal Tolerance
(Gallons) (Vdc) (Vdc)
0 0.00 ±.20
40 3.33 i 20
80 6.67 *.20
120 10.00 *.20
P/N 115.115 (115.115-3) Performance Test Requirements
Table 102

(4) Performance Test (P/N 115.115-1 and 115.115-4)

(a) Connect indicator UUT to DC Calibrator from pins 4 (+) and 3 (-) of
UUT connector PI. Allow for sufficient UUT and test equipment
warmup time.

(b) Verify that the calibrator is set to zero. Raise the calibrator voltage until
the meter reads 160 gallons. Apply calibrator voltages as shown in Table
103 and very that meter indication agrees (within tolerances) with those
listed.

(c) Shut off power and disconnect DC Calibrator from indicator UUT.

Meter Indication Nominal Tolerance

(Gallons) (Vdc) (Vdc)
0 0.00 *.20
40 -3.08 ±.20
80 -5.27 + 20
120 -7.35 *.20
160 10.00 *.20
P/N 115.115-1 (115.115-4) Performance Test Requirements
Table 103

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115
C. Fault Isolation Analysis

(1) Procedure

Isolate an indicator fault/malfunction in accordance with Table 104, Fault

Isolation Analysis (assistance chart).

(a) If the indicator fails to pass accuracy testing described in the TESTING
portion of this section, perform calibration procedures stated in the
FAULT ISOLATION ANALYSIS guide prior to performing fault
isolation analysis of the indicator itself.

(b) Most problems in the indicator can be identified by performing a

systematic check of the electronic circuitry to locate the defective
component. Refer to the schematic diagram, Figure 101, for applicable
test points. Visually check for opens in the wiring, as well, prior to
examination of the remainder of the indicator unit.

MALFUNCTION PROBABLE CAUSE POSSIBLE SOLUTION

LAMP TEST
Lamps burned out Replace lamp housing assy (5, IPL)
Lamps do not illuminate
Wiring from lamps to pins I and 2 Replace defective wiring (see repair)
shorted or burned out
Lamp contacts bent or broken Replace TBA (45, IPL 1001)

STATIC BALANCE TEST

Meter assembly defective; pointer Replace meter assembly (25, IPL)
Pointer deflection exceeds 1% of full
scale; pointer position incorrect | unbalanced
PERFORMANCE TEST
Meter assembly defective Replace meter assembly (25, IPL)
Pointer sticks or fluctuates
Wiring between meter and CBA or CBA Replace defective wiring (refer to
to connector damaged/shorted Repair section of this CMM)
RlI/R2 open Test with multimeter and replace failed
No meter indications
part as required (See Repair)
R3 shorted Test with multimeter and replace failed
part as required (See Repair)
Meter Ml failed/defective Replace meter assembly (25, IPL)
Pointer misadjusted Set pointer to correct position. See
Incorrect/improper meter indication
assembly section of this CMM
RI/R2 open Test with multimeter and replace failed
part as required (See Repair)
R3 shorted Test with multimeter and replace failed
part as required (See Repair)
Meter improperly calibrated Recalibrate meter per Assembly
Fault Isolation Analysis
Table 104

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

SIGNAL R2
RNN
1/2WWW PAD
PAD 1%

0-10 voc R3 ml
20K
1%

SIGNAL(
INPUT
5VACI
LIGHTING 053
3S2
SSI
5V RTN 2

CASE GNO

Schematic Diagram
Figure 101

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

DISASSEMBLY

CAUTION: DISASSEMBLE THE POTABLE WATER QUANTITY INDICATOR IN A

CLEAN, DUST-FREE AREA. PROTECT PARTS FROM MOISTURE,
CONTAMINANTS AND OTHER DAMAGE BY PLACING IT IN A COVERED
CLEAN, NON-STATIC CONTAINER AFTER DISASSEMBLY.

NOTE: Refer to TESTING AND FAULT ISOLATION section to determine most probable
cause of any malfunction. Disassemble only to the extent required to correct the
problem. Inspect visually and perform testing and Fault Isolation prior to disassembly.
A. All items referenced throughout this section refer to IPL Figure 1001, unless otherwise
noted.
B. To disassemble the Potable Water Ouantity Indicator, proceed as follows:
NOTE: It is recommended that the Potable Water Quantity Indicator be returned to
Rogerson Aircraft Corp. for the appropriate maintenance to be performed in the
event extensive maintenance or repair of that assembly is required.

NOTE: Do not remove the indicator nameplate unless necessary to do so.

(1) Remove lamp housing assembly (5, IPL Fig. 1001) from case (10) by unscrewing
two captive screws.
(2) Remove case (10) from frame (120) by removing four screws (15).
(3) Remove and discard 0-ring (100).
(4) Remove insulation (20) from case (10).

NOTE: Do not remove terminal board assembly unless determined defective (refer to
TESTING section.)
(5) Remove terminal board assembly (45) by removing two screws (50), two lock-
washers (55) and two flat washers (60). Unsolder and remove brown and red
wires from terminal board assembly (45). Note position of meter assembly to
facilitate reassembly.
(6) Using a low wattage (25 to 40W) soldering device, tag and unsolder red and black
wires from meter to CBA (70).

(7) Remove meter assembly (25) by removing two screws (30), lockwashers (35), and
washers (40). Remove four spacers (65).

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PART NO. 115.115

C. Removal of Printed Circuit Board Assembly and Connector

(1) Perform the disassembly as detailed in the preceding paragraphs.

(2) Note position, mounting, routing and clipping of wires for facilitating reassembly.

(3) Using the soldering device, tag and unsolder orange and yellow wires from PCBA
(70) to connector (105).

(4) Remove PCBA (70) by removing two screws (75) and lockwashers (80).

(5) Remove solder lug (90) by removing screw (85) and lockwasher (90).

NOTE: Connector mounting screws are secured with hydraulic sealant. Some force may
be required to loosen the screws. If screws cannot be loosened easily, heat screws
with the soldering device sufficiently to ease in removal of the screws.

(6) Remove connector (105) from frame (120) by removing four screws (110).
Remove and discard gasket (115).

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

CLEANING

NOTE: Clean Potable Water Quantity Indicator in a clean, dust-free area.

A. Cleaning Requirements

The materials listed in TABLE 401 are required for cleaning.

NOTE: Equivalent substitutes may be used for listed items.

MATERIAL SPECIFICATION
Solvent, Stoddard Federal Standard P-D-680
Alcohol, Isopropyl (or glass cleaner) Commercially Available
Brush, Soft Bristle Commercially available
Brush, Static Commercially available
Cloth, Line-Free Commercially available
Cleaning Materials
Table 401

B. Cleaning Procedures

WARNING: USE SOL VENTS INA WELL VENTILA TED AREA. KEEP WAY
FROM OPEN FLAME. A VOID INHALA TION OF FUMES OR
PROLONGEDCONTACT OF SOLVENT WITH SKIN

(1) External Cleaning

(a) Clean outside of case (10, IPL Fig. 1001) with a soft bristled brush
moistened with Stoddard solvent. Wipe dry with a clean, lint-free cloth

(b) Clean case lens with glass cleaner or isopropyl alcohol and a clean, lint-
free cloth. Dry thoroughly with a clean, dry, lint-free cloth.

(c) Clean connector assembly (105) with a soft bristled brush moistened with
solvent.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

(2) Internal Cleaning

CAUTION: DO NOT PERFORM INTERNAL CLEANING UNLESS

UNIT HAS BEEN DISASSEMBLED FOR REPAIR.
PERIODIC INTERNAL CLEANING OF TRANSMITTER
AS A MAINTENANCE FUNCTION IS NOT REQUIRED.
ENSURE METER MOVEMENT HAS BEEN REMOVED
PRIOR TO CLEANING THE INDICATOR INTERN-
ALLY. IF FOREIGN MATTER IS LODGED IN THE
METER MOVEMENT, RETURN THE MOVEMENT TO
ROGERSON AIRCRAFT. THE CASE LENS IS PRO-
TECTED WITH AN ANTI-REFLECTIVE COATING. DO
NOT APPLY SOLVENT TO LENS OR THE COATING
MAY BE DAMAGED. AVOID ANY SCRATCHING.

(a) Clean inside of case (10) with a soft bristled brush moistened with
Stoddard solvent Dry thoroughly with a clean, lint-free cloth

(b) Clean inside of case lens with glass cleaner or isopropyl alcohol and a
clean, lint-free cloth. Dry thoroughly with a clean, dry, lint-free cloth
Brush dried lens with a static brush to remove any excess static buildup.

(c) Clean Mounting Board Assembly (70) and inside of connector (105) with
a soft bristled brush moistened with isopropyl alcohol. Air dry or dry
with clean, soft shop cloth.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

CHECK

A. General

Refer to IPL, Figure 1001 and check all parts for obvious defects in accordance with
industry standards.

NOTE: Periodic inspection of the indicator assembly components is not required.

Perform internal check when the indicator has been disassembled for
repair.

B. General Visual Check

(1) Visually check all parts for burrs, nicks, scratches, abrasions, gouges
and/or corrosion.

NOTE: Burrs, nicks and scratches are defined as material raised above normal
surface, which, if not removed would prevent complete and proper mating
of parts and sealing surfaces.

(2) Visually check any threaded parts for crossed or otherwise damaged threads.

(3) Visually check seating and mating surfaces for corrosion or damage.

C. External Check of Potable Water Ouantitv Indicator Assembly

Check Water Quantity Indicator ,( IPL Figure 1001), as follows:

(1) Check indicator case for any sign of broken pins, scraping or deformation of
mating surfaces. Replace case if necessary, referring to Disassembly and
Assembly sections of this CMM.

(2) Check indicator connector assembly (105) for loose, bent, broken or missing pins.
Replace connector assembly if defective (refer to Disassembly and Assembly
sections of this CMM).

D. Internal Check of Potable Water Ouantitv Indicator Assembly

CAUTION: DO NOT PERFORM INTERNAL CHECK UNLESS INDICATOR

HAS BEEN DISASSEMBLED FOR REPAIR. PERIODIC IN-
SPECTION OF INTERNAL COMPONENTS NOT REQUIRED.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

(1) Check Printed Circuit Board Assembly (PCBA) for any sign of damage,
overheating, component dislocation, disconnection or deformation. Note location
and type of component (part) and identify per the appropriate IPL illustration.

(2) Inspect PCBA for breaks, shorts, or peeling of circuit traces. Repair or replace
any defective PCBA as is necessary.

(3) Check wiring for any sign of wear, wicking of solder at wire ends, breakage,
burns, broken solder joints of other common wire damage. Inspect electrical
connector and banana plug for frayed or burned insulation. Replace any defective
wires in accordance with the REPAIR Section in this CMM.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

REPAIR MATERIALS
NOTE: In Table 601, Repair Materials, uivalent substitutes may be used for listed items.
TOOLS/MATERIALS TYPE / SPECIFICATION
Emery paper No. 400 Grade; Commercially Available
Paint, Flat Brown Epoxy, BAC 8328 Finch (per Boeing specification)
Soldering Station 25-40 Watt capacity
Solder, 60/40 Tin-lead resin flux-core Federal Standard QQ-S-571
Desoldering Implement (Part of Solder Station) Suction, Commercially Available
Repair Materials
Table 601
2. REPAIR PROCEDURES

NOTE: External repair is limited to the following procedures.

NOTE: Internal repair is limited to replacement of failed. damaged or defective
parts as determined by CHECK procedures of the transmitter (IPL Fig.
1001). If defective, limited repair may be performed as noted in the
following procedures.
A. Replace all worn or damaged parts that cannot be repaired to meet the requirements of
this section.

CAUTION: DO NOT USE CROCUS ABRASIVE CLOTH ON ALUMINUM

PARTS. CROCUS CLOTH CONTAINS AN IRON OXIDE
WHICH CAUSES RAPID OXIDATION OF ALUMINUM.
B. Polish minor external nicks, scratches and corrosion on transmitter case using appropriate
emery paper.

C. Clean all polished parts as instructed in CLEANING section.

D. Repair damage to anodized finish on aluminum parts by applying brush alodine to bare
polished areas. Reclean parts as instructed in CLEANING section.
E. Replace threaded parts if thread damage exceeds 50 percent of one thread. If thread
damage does not exceed 50 percent of one thread, chase threads with proper tap or die.
Routinely replace any standard fastener (screw, nut, etc.) at each removal regardless of
apparent condition.

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PART NO. 115.115

F. Return extensively damaged or defective PCBAs to Rogerson Kratos for repair. Repair on-
site if the specific repair is a routine component change which can be accomplished wit
out extensive removal of protective coating, ICs or small components.

G. Printed Circuit Board Assembly (PCBA) (70, IPL Fig.1001) Repair

The following general instructions apply to the repair of PCBAs (Refer to Figure 601
Wiring Diagram):

(1) Support the PCBA so it will not move or cause the soldering device to strike other
components, i.e. generally recognized shop practice.

(2) Use a clean low wattage (25 - 40W) solder station.

(3) Install components in the same location, angle, and attitude with relation to the
PCBA as original installation.

(4) Inspect and test all resoldered connections.

(5) Repair breaks in circuit traces by bridging with a piece of copper wire soldered to
the trace. Do not attempt to solder across the break otherwise. If the break is
non-repairable, replace the PCBA.

(6) Use desoldering equipment, such as a solder sucker, when unsoldering PCBA
components.

(7) Use heat sinks on transistor or diode leads when soldering or unsoldering parts or
wires on a PCBA.

(8) Clean area of excess scrap, excess solder, solder spatter, and/or resin overflow
after repairs.

H. Refer to the wiring diagram, Figure 601 for color and proper connection of wiring. Note
routing and clipping of wires prior to any wire removal. Remove damaged wires and
install new wires with 60/40 solder, using a 25 to 40 Watt soldering station.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

TERMINAL BOARD ASSEMBLY

CONNECTOR
LAMP HOUSING ASSEMBLY

1 BROWN -

2 RED-
- LAMPS

3 ORANGE METER

* BLUE BLACK

CASE GROUND PCBOARD RE}

4YELLOW(i
4

Wiring and Component Location Diagram, PCBA

Figure 601

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

1. ASSEMBLY

NOTE: The tools and materials listed in Table 701 are required in addition to
standard shop tools. The tools and materials listed are called out in
their appropriate procedures and are also called listed again in the
SPECIAL TOOLS. FIXTURES AND EQUIPMENT section along with
their sources.

A. Material and Equipment

NOTE: Equivalent substitutes may be used for listed items.

TOOLS/MATERIALS TYPE/SPECIFICATION MANUFACTURER

Soldering Iron 25 to 40 Watt Commercially Available
Solder 60/40 Tin-Lead, Resin Fed. Std. QQ-S-571 Commercially Available
Flux Core
Desoldering Tool Suction or wicking Commercially Available
Loctite Hydraulic 69-31 Loctite Corporation
Lubricant Super O-Lube Parker
Conformal Coating, Polyureth. PC 18 Hisol
Assembly Materials and Equipment
Table 701

B. Assembly Procedures (Ref Fieure 701)

All items referenced throughout this section refer to IPL Figure 1001, unless otherwise
noted.

C. To assemble the Potable Water Ouantitv Indicator, proceed as follows:

NOTE: It is recommended that the Potable Water Quantity Indicator be returned to

RAC for the appropriate maintenance to be performed in the event extensive
maintenance or repair of the assembly is required. Solder any components
removed from the PCBA with new components of the same value and type. Any
new board components and all repaired solder joints must be coated with the
polyurethane conformal coating (See Table 701) for indicator parts protection.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

(1) Assemble Printed Circuit Board Assembly

NOTE: Apply Loctite sealant to all screw threads prior to insertion into place.
(a) Install new gasket (115, Figure 1001) on connector (105). Apply
hydraulic sealant to threads of screws (110) and secure connector (105) to
firame (120) with four screws (110).
(b) Lubricate new 0-ring (100) with Super O-Lube and install groove in
frame (120). Attach solder lug (90) to frame (120) and secure with screw
(85) and lockwasher (95).
(c) Using the low wattage soldering device, solder wires as tagged during
disassembly to solder lug (90) and PCBA (70).
(d) Install the PCBA (70) on mounting frame (120). Secure in place with two
lockwashers (80) and screws (75).

(2) Installation of Meter Assembly

(a) Using a low-wattage (25 to 40W) soldering device, solder wires, as tagged
during disassembly, routed from the meter assembly (25) to PCBA (70).
(b) With meter assembly in position noted during disassembly, secure meter
assembly (25) and four spacers (65) to frame (120Z) using two screws
(30), lockwashers (35) and washers (40).

(c) Verify' that meter pointer is on first graduation. If not, use an Allen
wrench (or the straightened end of a metal paper clip). Insert into upper
hole in spring support as shown in Figure 701 and carefully adjust meter
movement until pointer is on first graduation.
(d) Install terminal board (45) and secure with two screws (50), two lock-
washers (55) and two flat washers (60). Solder brown and red wires as
tagged during disassembly.

(e) Perform calibration procedure described in next section.

(f) Install insulation (20) in case (10).

(g) Install case (10) on frame (120).

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

(h) Apply hydraulic sealant to threads of four screws (15) and install in case
(10).

(i) Install lamp housing assembly (5) in case (10) and secure with two
captive screws.

(I) Perform functional test after lights are on approximately 30 minutes.

D. Calibration Procedure

(1) Verify that meter pointer is set at zero indication. Adjust mechanical zero if
necessary.

(2) Connect DC Calibrator to indicator pins 3 (-) and 4 (+) at connector (105).

(3) Connect resistance decade boxes in place of resistors RI and R2 (see IPL Figure
1002) and set initial values as shown in the following:

DC Calibrator 10.00 Vdc

RI 500 Ohms
R2 15K Ohms

(4) Adjust decade R2 so that the indicator reads 120. From resistor kit 0349-202 1,
select appropriate RN55C resistor which will ensure nearest scale reading without
exceeding 120 reading.

(5) Disconnect DC Calibrator and R2 decade box.

(6) Reconnect calibrator and readjust RI so that indicator reads 120. From resistor
kit 0349-2009, select appropriate pad resistor which will ensure nearest scale
reading without exceeding 120 reading.

(7) Disconnect DC Calibrator and RI decade box. Install appropriate resistors and
confirm that calibration meets requirements of Performance Test.

(8) Shut off power.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

Meter Movement Adjustment

Figure 701

E. Storage After Assembly

(I) Storage Materials

Storage materials are listed in Figure 702.

NOTE: Equivalent substitutes may be used for listed items.

Material Type

Carton, Cardboard Commercially Available

Tape, Paper Commercially Available
Filler Kimpack
Paper Grade A
Storage Materials
Figure 702

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

(2) Storage Instructions

(a) Insert a layer of Kimpak at the bottom of a cardboard box.

(b) Wrap the transmitter in Grade A paper, place in carton

(c) Fill the remainder of space with Kimpak

(d) Close carton and seal with paper tape.

(e) Mark outside of carton with equipment nomenclature, part

number and date of repair
0
(f) Store in a dry area where temperatures remain between 55 F and
95°F (13CC and 35CC).

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

1. SPECIAL TOOLS. FIXTURES AND EQUIPMENT

A. Special Tools

None required

B. Fixtures

None required

C. Equipment

Refer to Table 901 for equipment required for specific procedures in the manual. They are
considered to be standard shop items and are commercially available. Suitable equivalents may
be used in place of the items listed. These items are also referenced in the appropriate steps and
in each applicable section.

NOTE: Equivalent substitutes may be used for listed items.

TOOL/EQUIPMENT MANUFACTURER CMM SECTION (RANGE)

DC Calibrator John Fluke Mfg. Co., Inc. Mountlake Testing, Assembly, 0 - 2OVdc
Terrace, WA
Resistance Decade Box (2) Commercially Available Testing (0 to 1K ohms)
DC Power Supply Commercially Available 0 to 5OVdc
Soldering Iron Commercially Available Disassembly/Assembly 2540W
Desoldering Tool Commercially Available Suction or wicking
Special Tools, Fixtures and Equipment
Table 901

D. The following, Table 902, is a list of the consumable materials required for specific
procedures in the manual. They are considered to be standard shop items and are
commercially available. These items are also referenced in the appropriate steps and in
each applicable section.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

CONSUMABLE MATERIALS

MATERIAL / TYPE SOURCE SECTION

Solvent, Stoddard Fed. Spec. P-D-680 Commercially Available Cleaning

Cloth, Lint-Free Commercially Available Cleaning
Brush, Soft Bristle Commercially Available Cleaning
Brush, Static Commercially Available Cleaning
Emery Paper No. 400 Grade Repair
Paint, Flat Brown Epoxy BAC 8328 Finch, Repair
Thinner, Paint Commercially Available Repair
Solder 60/40 Tin-Lead Resin Flux Core Fed. Std. QQ-S-571 Assembly
Loctite Hydraulic 69-31 Assembly
Lubricant Super O-Lube Assembly
Conformal Coating, Polyurethane Hisol PC 18 Assembly
Cleaner, Glass (or Isopropyl Alcohol) Commercially Available Cleaning
Bag, Polyethylene Commercially Available Storage, Shipping
Desiccant Commercially Available Storage, Shipping
Paper, Grade A Commercially Available Storage, Shipping
Container, Cardboard Commercially Available Storage, Shipping
Filler Commercially Available Storage, Shipping
Paper, Grade A Commercially Available Storage, Shipping
Tape, Paper Commercially Available Storage, Shipping

Consumable Materials
Table 902

E. Special Conditions; All work performed on the indicator should be in a clean dust-free
area.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

ILLUSTRATED PARTS LIST

A. Introduction and Purpose

(1) This section provides the illustration(s) and breakdown of parts for the
assembly(ies) which can be disassembled, repaired or replaced.

(2) This section contains a detailed list of six columns: Figure and Item, Part
Number, Airline Part Number, Nomenclature, Effectivity and Units per
Assembly.

B. Explanation and Usage

(1) The FIGURE and ITEM column lists the figure number and the item number
for each detail part. The figure number is listed once at the top of the column
and each part is called out by and item number. Any part which is not
illustrated will have an item number preceded by a dash (-)

(a) An alpha variant, letters A through Z (except I and 0) is assigned to

an item number when necessary to show:
1) Alternate parts
2) Service Bulletin changes
3) Configuration differences
4) Product improvement parts (non-service bulletin)

(b) An alpha variant item number is not shown on the exploded view
when the appearance and location of the alpha variant item is the same
as the basic item number.

(2) The PART NUMBER column lists the part number for each detail part. Use
the part number exactly as listed when procuring parts unless the part is
proprietary, which is indicated by a letter "P" preceding the vendor code
number. (Refer to paragraph D in this section).

(3) The AIRLINE STOCK NUMBER column is provided for individual airline
use.

(4) The NOMENCLATURE column describes the detail part. A vendor code is
provided if the part is not manufactured by Rogerson Aircraft Corporation. If
vendor codes are used, the name and address for each vendor is listed at the
end of this introduction.

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COMPONENT MAINTENANCE MANUAL
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The parts descriptions in the nomenclature column are indented to depict the
relationship of the part to the next higher assembly. For example:

1234567

Top Assembly
Attaching Parts
Deleted Parts
. Detail Parts for Top Assembly
. Subassembly
. . Detail Parts for Subassembly
Attaching Parts
. . . Sub-subassembly
.... Detail Parts for Sub-subassembly

(5) The EFFECTIVITY CODE column is used to show additional configurations

to the top assembly. Each configuration is assigned a code letter (letters A
through Z, except I and 0). All detail parts associated with a configuration are
coded with the same letter. A blank space in the effectivity column indicates
that the detail part is used on all configurations of the top assembly.

(6) The UNITS PER ASSEMBLY column lists the total quantity of each part
required. The letters AR indicate that the quantity required will be determined
during assembly procedures. The letters RF indicate that the item is listed for
reference purposes only.

C. Part Replacement Data.

(1) The interchangeability relationship between parts is identified in the

NOMENCLATURE column. A list of the terms used and their definitions is
listed in the following chart.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

TERM ABBREVIATION DEFINITION

Alternate ALT The part is a substitute for another
part with equal value, weight,
dimension, etc; can be noted with
certain specifications or complete
interchangeablity.

Interchangeable INT The part is completely equal to other

variants listed without any differing
specifications. It may be used in any
instance where the alternate part is
referenced.

Optional OPT The part is interchangeable with

other parts in the same item number
variant group, or with another item
number listed in the notation.

Preferred PRFD The part is first choice over the

alternate parts listed.

Source Control Drawing SCD Component part is manufactured as

proprietary under controlled design
specifications by outside vendor
manufacturer.

Superseded by SUPSD BY The part is replaced by and is not

interchangeable with the item
number in the notation.

Supersedes SUPSDS The part replaces and is not

interchangeable with the item
number in the notation.

D. Proprietary

An item listed in the nomenclature column of the illustrated parts list which is
proprietary to the component manufacturer (Rogerson Aircraft Corporation) is
identified by the letter "P" preceding the vendor code number. This item may be
listed with more than one model or part number but is identified by the component
manufacturer's source controlled part number which is to be used for any parts
procurement specification.

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

E. Vendor Information

The following list contains the name and address of each vendor whose code number
is listed in the nomenclature column of the illustrated part list or is listed in other
sections of this manual in alphanumeric order.

CODE NAME AND ADDRESS

V02660 Bunker Ramo Corp.
Amphenol Connector Div.
2801 S. 25th Ave.
Broadview, IL 60153

V34830 Rogerson Kratos

403 South Raymond Avenue
Pasadena, CA 91109

V77820 Bendix
Electrical Components Division
Sidney, NY 13838

V83259 Parker-Hannifin Corp.

O-Seal Division
10567 Jefferson Blvd.
Culver City, CA 90230

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COMPONENT MAINTENANCE MANUAL Ila
PART NO. 115.115

I5

NOTE: 0
DIAL FACE ROTATED 135 DEGREES

CLOCKWISE FOR CLARITY. 1

65
5 70

80

15
85

40 /
45

0~u 1 15/00i

Potable Water Quantity Indicator 115.115

IPL Figure 1001

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

FIG. & AIRLINE EFF UNITS

ITEM PART NO. PART NO. 1 2 3 4 5 6 7 NOMENCLATURE CODE PER
NO. ASSY
1-1 115-115 INDICATOR, POTABLE WATER QUANTITY A RF
-IA 115-115-1 INDICATOR, POTABLE WATER QUANTITY B RF
-I1B 115.115-3 INDICATOR, POTABLE WATER QUANTITY C RF
-IC 115.115-4 INDICATOR, POTABLE WATER QUANTITY D RF
5 0312-0469 * HOUSING ASSY, LAMP I
10 0305-0704 * CASE ASSY 1
ATTACHING PARTS
15 0349-0009 * SCREW 4

20 0317-0106 * INSULATION 1
25 0356-0551 * METER ASSEMBLY, PRE SB115.115-38-02 A 1
-25A 0356-0795 * METER ASSEMBLY, PRE SB 115.115-38-02 B I
-25B 0356-0836 * METER ASSEMBLY, POST SBI15.115-38-02 B,D I
-25C 0356-0846 * METER ASSEMBLY, POST SB] 15.115-38-02 A,C I
ATTACHING PARTS
30 2840-9206 * SCREW, (V34830) 2
35 2833-0504 * WASHER, LOCK 2
40 2833-1004 * WASHER, FLAT (V34830) 2

45 0307-0528 * * BOARD ASSEMBLY, TERMINAL 1

ATTACHING PARTS
50 2840-9103 ** SCREW (V34830) 2
55 2840-0503 * LOCKWASHER (V34830) 2
60 2833-01003 * WASHER, FLAT (V34830) 2

65 0329-0058 * SPACER 4
70 0307-0523 * BOARD ASSY, PRINTED CIRCUIT (SEE FIG. 1002 FOR BDN) 1
ATTACHING PARTS
75 28404104 * SCREW (V34830) 2
80 2833-0503 * LOCKWASHER (V34830) 2

85 28404103 * SCREW (V34830) 1

90 2143-0002 * LUG, SOLDER 1
95 2833-0503 * LOCKWASHER (V34830) 1
100 2550-2701 * O-RING (V83259) l
105 2115-0043 * CONNECTOR (V02660) 1
ATTACHING PARTS
110 2840-3304 * SCREW 4
as.....

115 2516-0005 * GASKET(V77820) I

120 0315-0763 * FRAME 1
- ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

Q R3 R2 RI

25

15 30 la 5 20

Printed Circuit Board Assembly (PCBA)

IPL Figure 1002

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COMPONENT MAINTENANCE MANUAL
PART NO. 115.115

FIG. & AIRLINE EFF UNITS

ITEM PART NO. PART NO. 1 2 3 4 5 6 7 NOMENCLATURE CODE PER
NO. ASSY

2-1 0307-0523 BOARD ASSEMBLY, PRINTED CKT (REF IPL 1001, NHA) RF
5 4753-XXXX * RESISTOR, PAD, WW RI 1% 1/2W (SEE FOOTNOTE 1) I
-5A RNC55CXXXXFS * RESISTOR, PAD, FF, EST. RELI., 1% 1/10W (ALTERNAT.) I
10 4755-XXXX * RESISTOR, PAD, FF R2 1% 1/IOW (SEE FOOTNOTE 2) 1
-10A RNC55CXXXXFS . RESISTOR, PAD, FF EST. RELI. 1% 1/10W (ALTNERA.) 1
15 RN55C2002F . RESISTOR, FF R3 20K 1% 1/102 (V34830 PN 4755-2002) 1
15A RNC55C2002FS * RESISTOR, FF EST. RELI. 20K 1% 1/10KW (ALTERNAT.) 1
20 2148-0007 * TERMINAL 7
25 0329-0053 * SPACER 2
30 0306-0394 1 1 * BOARD, PRINTED CIRCUIT I

- ITEM NOT ILLUSTRATED

1= Resistor selected at time of calibration from resistor kit 0349-2009. Kit consists of 500 resistors
conforming to RK drawing 4753-XXXX as follows:

I resistor each ohm from 1to 200 ohms = 200 resistors

1 resistor each 2 ohms from 202 to 500 = 150 resistors
1 resistor each 3 ohms from 503 to 800 = 100 resistors
1 resistor each 4 ohms from 804 to 1000= 50 resistors
500 resistors

2= Resistor selected at time of calibration from resistor kit 0349-2021.

Kit consists of 171RN55C type 1% resistors in standard value steps from 1K to 60K
conforming to Rogerson Kratos drawing 4755-XXXX.

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