Tech_Data_Specs.pdf

REPAIR AND FABRICATION OF SEAT PART MATERIALS

5.1. General.

A. This section contains the following procedures for repair and fabrication of seat materials for the fol-lowing Part Numbers:

Part Number Cage Code Noun, Description

0A326-0201 K9075 Headrest Assembly

0A326-0203 K9075 Cushion Assembly, Back

0A326-0207 K9075 Cushion Assembly, Pan

0A326-0209F K9075 Cover Assembly, Pan

1A326-0205F K9075 Cover Assembly, Back Cushion

1A326-0213F K9075 Upholstery Assembly, Armrest

1A326-0321F K9075 Upholstery Assembly, Rotational Pad

1A326-0459F K9075 Upholstery Assembly, Headrest

104044-1 54786 Seat Pan Assembly

103231-2 00679 Cushion Assembly, Seat Back

103234-2 00679 Cushion Assembly, Seat Pan

104052-1, -2 54786 Cushion Foam, Back and Head Rest

B. Identify new seat materials with the same part number and appropriate material specification.

C. Maintenance personnel should familiarize themselves with referenced drawings and specifications be-fore starting the fabrication process.

D. Review applicable drawings to identify which Standard Method drawings defined (ASTM, FED-STD, etc.) are applicable. Standard Method drawings define the materials and process specification neces-sary to fabricate the desired seat parts or materials.

E. Figures 5-1 thru 5-8 contain the illustration of seat parts configurations, providing the parts material descriptions and illustration references.

(1) Number on the index column assigned to the part in order to determine an exact location and allow cross referencing between illustration and text.

(2) Drawing/part number listed under this column is either seat part assembly or part detail of the seat part assembly configuration.

(3) Description, Gage and Size column describe each seat part material or item. It also contains the assigned nomenclature that appears in the title block of the engineering drawing, along with the modifiers and descriptive information to completely identify the item.

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THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

(4) Material or Make From column contains the description of the material, specification, and information used to fabricate the part.

(5) Reference column contains boxed letter assigned to seat part assembly configuration on text, to cross reference to illustration.

5.2. Check.

A. Inspect fabric for damage, wear and tear.

5.3. Repair.

A. General

(1) Repair is not applicable. Fabricate and replace assembly when damaged.

5.4. Fabrication.

A. General.

(1) Use drawing as reference when creating template for the part.

NOTE:

Existing fabric may be used as a pattern when cutting and marking location of the fold lines.

(2) Cut cloth and fastener tapes In Accordance With (IAW) dimension specified in the drawing.

(3) Determine type of seam to be used on location specified on the drawing; melt-seal web ends.

NOTE:

● Stitches, seams and stitching are per FED-STD-751.

● Type 301, 7 to 11 stitches per inch using thread is used.

● Stitch lines must be visible as two separate lines on double row stitches.

(4) Install fastener tapes on location specified on fabrics per drawing; stitch tapes per A-A-55126B.

B. Fabricate back and head rest cushion foam Part Number 104052 (ref. Figure 5-4) follows:.

NOTE:

● The headrest rest cushion foams (PN 104052-2) consist of a simple cut out piece of AIR- FLEX foam.

● The backrest cushion foam consists of the AIRFLEX foam. Optional method of fabricating

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the foam core is to cut the AIRFLEX foam into one piece per measurement indicated on the drawing in lieu of cutting one large and two small pieces.

(1) When fabricating headrest foam (3) and backrest foam (1), using the optional method, cut AIRFLEX foam (No. 9, Table A-1) in accordance with the dimension per drawing (ref. Figure 5-4).

(2) Fabricate backrest foam (1) as follows:

a. Cut one large piece and two small pieces of AIRFLEX foams (No. 9, Table A-1) in accordance with the dimension per drawing.

b. Using a spatula, apply thin layer of adhesive (No. 10, Table A-1) between the mating surfaces of the foams to be bonded.

c. Place, one at a time, small Airflex foams (No. 9, Table A-1) to bond on the location on large piece of Airflex foams. Allow adhesive on bonded foams to cure at room temperature.

C. IPECO Seat Covers and Cushion Foams.

(1) The following are IPECO Reference Documents for seat cover parts and foam fabrication:

Document Number CAGE Title

ES 056 K9075 Hook & Loop Colour Requirements (Engineering Specification)

Work Instruction (WI) 36B

K9075 Adhesive’s Guide

1A001-1769 K9075 Upholstery Material Code

D. Fabricate upholstery assembly (seat cover) and/or foam as follow (see Figures 5-5 thru 5-8):

(1) Fabricate seat upholstery or cover assembly as follows:

a. Use drawing or existing upholstery assembly as reference when creating template for the part.

NOTE:

● Existing fabric may be used as a pattern when cutting and marking location of the fold lines when fabricating seat covers.

● Bonding of cover materials, plastazote, and foams used are IAW Benson Lund Work Instruction 36B.

● Hook and loop fasteners requirements are IAW ES 056 (CAGE K9075).

● Cover assembly and foam templates can be made as per sample.

b. Cut fabric and loop and/or hook fastener tapes IAW dimension specified in the drawing or tem-plate.

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c. Determine type of seam to be used on location specified per existing fabric template; melt-seal web ends.

NOTE:

● Installation of loop and/or hook fastener tapes can be sewn or glued to the uphol-stery.

● When stitching method is to be used, seams and stitchings are per FED-STD-751.

● Type 301, 7 to 11 stitches per inch using thread is used.

● Stitch lines must be visible as two separate lines on double row stitches.

● All loop fasteners are to be sewn or glued on inside of cover assembly when in-stalling.

d. Install loop and hook fasteners on location specified on fabrics per template; if to be sewn, stitch fasteners per A-A-55126B; and install IAW WI 36B if fasteners are to be glued.

(2) Fabricate foam as follows:

NOTE:

Foam part number 3A520-XXXX series is an upholstery item. Complete specification of item is per Benson Lund Quality Dept. CAGE KC174.

a. Cut foams (4, Figure 5-5, 7, Figure 5-6, and 3, Figure 5-8), cushions (8, 9, Figure 5-7) or plastazote (4, Figure 5-8) IAW the dimensions per template.

b. Clean foam or cushion surfaces by blowing with clean, dry compressed air (30 psi).

c. Using a brush, apply adhesive (No. 14, Table A-1) to foam or cushion faying surfaces.

d. Allow adhesive to dry until tacky.

NOTE:

Time allowance is 5 to 10 minutes minimum to dry before joining.

e. Join foams or cushions with firm hand or roller pressure.

NOTE:

● No air should be trapped when joining two surfaces together.

● Clamping can be used while curing when bonding foams or cushions.

f. Allow 24 hours to cure.

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Figure 5-1. Seat Pan Assembly (Sheet 1 of 2)

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Index Drawing/Part Number

Description, Gage and Size Material or Make From

Reference

104044-1 Seat Pan Assembly [8] [9] [1] 1 103633-1 Fabric [2] [3] 2 103282-1 Fabric, Aramid [2] [4] 3 V-T-295 Thread [2] [5] 4 Fastener, Tape, Hook, 2.0 in. wide [2] [6] 5 Fastener, Tape, Pile, 2.0 in. wide [2] [6] 6 Webbing, 1.0 in., 0.025-0.040 in. Thk. [2] [7]

[1] Parts Manufactured by BAE System Aero, CAGE 54786.

[2] As required; number of pieces and length to be determined on assembly.

[3] Aramid Fabric, Water/Stain Resistant, 9-11 oz/sq yard material; Vertical Burn Test per FAR 25.853(b), 1988 Rev compliant.

[4] Flame Resistant Fabric, Color Black material; Vertical Burn Test per FAR 25.853(b), 1988, Rev compliant.

[5] Black Nylon; Material per V-T-295, Type II, Class A, Size E.

[6] Material per A-A-55126B, Type II, Class I, Black; Superseding MIL-F-21840.

[7] Material per MIL-W-4088 or MIL-W-27265, Class R or Class L, Color Red.

[8] All stitches, seams and stitchings are per FED-STD-751; for double-row stitches, stitch lines must be visible as two separate lines.

[9] Melt seal web ends; no bare fabric edges to be visible on outside finish product.

Figure 5-1. Seat Pan Assembly (Sheet 2)

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Figure 5-2. Seat Back Cushion Assembly (Sheet 1 of 2)

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Description, Gage and Size Material or Make From

Reference

103231-2 Seat Back Cushion Assembly [3] [7] [1] 1 103232-1 Core Assembly, Seat Back [3] 1 103817-1 Core Assembly, Seat Back [3] [10] 2 103287-1 Fabric, Upholstery [2] [3] [8] [11] 3 Tape, Pile Fastener, 3/4 in. wide [2] [3] [9] [4] 4 Thread [2] [3] [5] 5 103282-1 Fabric, Aramid [2] [3] [6]

[1] Parts Manufactured by Castle Industries of California, CAGE 00679.

[2] As required; number of pieces and length to be determined on assembly.

[3] Must meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Material per A-A-55126, Type II, Class I, Color Black; superseding MIL-F_21840.

[5] Manufactured from Polyester, Blue Color to match # 15180 per FED-STD-595. Material per MIL-DTL-32072, Type II, Class I, Size E; superseding V-T-285.

[6] Part is alternate to PN 103633-1, CAGE 00679.

[7] All seams to be type SSa-1 and stitching type 301 per FED-STD-751; 6 to 8 stitches per inch.

[8] All perimeter edges of fabric to be finished per FED-STD-751, Seam type EFd-1 and Stitching type 505.

[9] Edge distance for stitching fastener tape will be 1/16 to 1/8 inch.

[10] PN 103817-3, Back Cushion Assembly is an alternate part.

[11] Use approved material when fabricating part(s); Refer to drawing for approved material list.

Figure 5-2. Seat Back Cushion Assembly (Sheet 2)

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Figure 5-3. Seat Pan Cushion Assembly (Sheet 1 of 2)

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Description, Gage and Size Material or Make From

Reference

103234-2 Seat Back Cushion Assembly [3] [7] [11] [1] 1 103816-1 Core Assembly, Seat Pan Cushion [4] 2 103287-1 Fabric, Upholstery [2] [3] [9] [10] 3 Tape, Pile Fastener, 0.75 in. wide [2] [3] [5] [8] 4 Thread, Blue Polyester [2] [6] 5 Tape, Pile Fastener, 1.5 in. wide [2] [3] [5]

[1] Parts Manufactured by Castle Industries of California, CAGE 00679.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Use approved material when fabricating part(s); refer to drawing for approved material list.

[5] Material per A-A-55126, Type II, Class I, Color Black; Superseding MIL-F-21840.

[6] Color Blue to match #15180 per FED-STD-595; material per specification MIL-DTL-32072, Type II, Class I, Size E; Superseding V-T-285.

[7] All seams to be type SSa-1 and stitching type 301 per FED-STD-751; 6 to 8 stitches per inch.

[8] All perimeter edges of fabric to be finished per FED-STD-751, Seam type EFa-1 and Stitching type 505.

[9] Edge distance for stitching fastener tape will be 1/16 to 1/8 inch.

[10] Approved material to use is Discovery #21 blue dot, Anton Maix Fabric Inc., Ft Lauderdale, Fl.

[11] All finished cover should fit all parts of cushion when installed on the seat frame.

Figure 5-3. Seat Pan Cushion Assembly (Sheet 2)

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Figure 5-4. Back and Head Rest Cushion Foam (Sheet 1 of 2)

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Description, Gage and Size Material or Make From

Reference

104052 Cushion Foam, Back and Head Rest [1] [4] 1 104052-1 Foam, Backrest [1] [2] [3] [5] [6] [7] [A] 2 Adhesive [2] [3] [8] 3 104052-2 Foam, Headrest [1] [2] [3] [5] [7] [B]

[1] Parts Manufactured by Simula, Government Products Inc of Phoenix, Arizona, CAGE 54786.

[2] As Required; Amount to be used to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(a), 12 Second Burn.

[4] Use Approved material when fabricating part(s); refer to drawing for approved material list.

[5] Material: Open Cell Polychloroprene Foam Compound; Stiffness Indentation Load Deflection (ILD) = 30 to 40;

Nominal Density = 2.6 to 3.2 PCF; 0.75 Thk.

[6] Material (Applicable for Alternate Method of Fabrication): Open Cell Polychloroprene Foam Compound; Stiffness Indentation Load Deflection (ILD) = 30 to 40; Nominal Density = 2.6 to 3.2 PCF; 1.5 Thk. (Only applicable when using alternate method of fabrication).

[7] Approved Material: AIRFLEX Foam, Manufactured by Chestnut Ridge Foam, Latrobe, PA, CAGE Code 48818.

[8] Approved Material: 1300L Adhesive, Manufactured by 3M Co., St. Paul MN, CAGE Code 04963.

Figure 5-4. Back and Head Rest Cushion Foam (Sheet 2)

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Figure 5-5. Headrest Upholstery and Foam (Sheet 1 of 2)

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Description, Gage and Size Material or Make From

Reference

1A326-0459F Upholstery Assembly, Headrest [3] [1] [A] 0A326-0201 Headrest Assembly [3] [1] [B]

1 1A326-0459AY Material, Cover [2] [3] [4] [A] 2 3A505-0001 Fastener, Hook, 15 mm. [2] [3] [5] [A] 3 3A505-0002 Fastener, Loop 15, mm. [2] [3] [5] [A] 4 3A520-0005 Foam [2] [3] [6] [B] 5 3A520-0011 Plastazote, Foam [2] [3] [7] [A]

[1] Parts Manufactured by IPECO, CAGE K9075.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Made from leather, Color Pacific Blue per material code 1A001-1769AY. Part manufactured by Bridge of Weir, CAGE U2472.

[5] Color Grey per IPECO requirements specification ES056. Material to be sewn or glued.

[6] Part identification is NG32/3, Special Application Foam (Brown). Specification information per Benson Lund, CAGE KC174.

[7] Part identification is LD45FR. Specification information per Benson Lund Quality Dept. CAGE KC174.

Figure 5-5. Headrest Upholstery and Foam (Sheet 2)

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Figure 5-6. Back Cushion Cover and Foam (Sheet 1 of 3)

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Figure 5-6. Back Cushion Cover and Foam (Sheet 2)

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Description, Gage and Size Material or Make From

Reference

1A326-0205F Cover Assembly, Back Cushion [3] [1] [A] 0A326-0203 Cushion Assembly, Back [3] [1] [B]

1 1A326-0205HX Material, Cover [2] [3] [4] [A] 2 3A505-0004 Fastener, Loop 20 mm. [2] [3] [5] [A] 3 3A505-0003 Fastener, Hook 20 mm. [2] [3] [5] [B] 4 3A505-0008 Fastener, Loop 50 mm. [2] [3] [5] [B] 5 3A520-0007 Nylon [2] [3] [6] [B] 6 3A520-0023 Scrim [2] [3] [7] [B] 7 3A520-0031 Foam [2] [3] [8] [B]

[1] Parts Manufactured by IPECO, CAGE K9075.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Part is made from Sheepskin and Trevira Cloth; Sheepskin in body contact area, Color: Pacific Blue. Manufactured by Sleepmaster; made from Trevira Cloth on remaining area, Color: Blue, Manufactured by Concept Fabrics, Inc.

[5] Color Black and to be sewn or glued on material cover.

[6] Upholstery item. Material is made from Nylon (White), part identity is 4 oz AHV 504 per IPECO, CAGE K9075.

[7] Upholstery item. Material is made from Polyester Scrim (White), part identity is PK186 per IPECO, CAGE K9075.

[8] Upholstery item. Material is made from foam, part identity is MP55 per IPECO, CAGE K9075.

Figure 5-6. Back Cushion Cover and Foam (Sheet 3)

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Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 1 of 4)

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Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 2)

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Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 3)

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Description, Gage and Size Material or Make From

Reference

0A326-0209F Cover Assembly, Pan Cushion [3] [1] [A] 0A326-0207 Cushion Assembly, Pan [3] [1] [B]

1 0A326-0209HX Material, Cover [2] [3] [4] [A] 2 3A521-0001 Button, Push Fastener [5] [A] 3 3A521-0009 Socket, Push Fastener [5] [A] 4 3A521-0013 Stud, Push Fastener [5] [A] 5 3A521-0015 Eyelet, Push Fastener [5] [A] 6 3A505-0002 Fastener, Loop 15 mm. [2] [3] [6] [A] 7 3A505-0005 Fastener, Loop 30 mm [2] [3] [6] [A] 8 0A326-0517 Cushion, Seat Pan [2] [3] [7] [B] 9 1A326-0519 Cushion, Thigh Pad [2] [3] [8] [B] 9A 1A326-0520 Cushion, Thigh Pad [2] [3] [8] [B] 10 3A505-0001 Fastener, Hook 15 mm. [2] [3] [6] [B] 11 3A505-0003 Fastener, Hook, 20 mm. [2] [3] [6] [B] 12 3A505-0005 Fastener, Hook 30 mm. [2] [3] [6] [B] 13 3A505-0008 Fastener, Loop 50 mm. [2] [3] [6] [B] 14 3A505-0006 Fastener, Look 30 mm. [2] [3] [6] [B] 15 3A520-0007 Nylon [2] [3] [9] [B] 16 3A520-0033 Thread [2] [3] [10] [B] 17 3A520-0012 Fabric, Fire Blocking [2] [3] [11] [B]

[1] Parts Manufactured by IPECO, CAGE K9075.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Part is made from Sheepskin and Trevira Cloth; Sheepskin in body contact area, Color: Pacific Blue. Manufactured by Sleepmaster; made from Trevira Cloth on remaining area, Color: Blue, Manufactured by Concept Fabrics, Inc.

[5] Made from Nickel Plate Finish. Manufactured by Benson Lund, CAGE KC174.

[6] Color: Black; to be sewn or glued on material cover.

[7] Made from material Vastipur W5450; Cushion Hardness to be 350 to 420 Newton at 50% Relative Humidity.

[8] Made from material Vastipur W5450; Cushion Hardness to be 200 Newton +- 10% at 50% Relative Humidity.

[9] Upholstery item. Material is made from Nylon (White), part identity is 4 oz AHV 504 per IPECO, CAGE K9075.

[10] Upholstery item. Material is made from Kevlar ECRU thread, part identity is TEX-50-2 per IPECO, CAGE K9075.

[11] Upholstery item. Material is made from Panotex Fire Blocking Fabric, part identity is P505 per IPECO, CAGE K9075.

Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 4)

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Figure 5-8. Crew Seat Arm Assembly Cover and Foam (Sheet 1 of 2)

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Description, Gage and Size Material or Make From

Reference

1A326-0213F Upholstery Assembly, Armrest [3] [1] [A] 1A326-0321F Upholstery Assembly, Rotational Pad [3] [1] [B]

1 1A326-0213AY Material, Cover [2] [3] [4] [A] 2 1A326-0321AY Material, Cover [2] [3] [4] [B] 3 3A520-0005 Foam [2] [3] [5] 4 3A520-0011 Plastazote, Foam [2] [3] [6] [A]

[1] Parts Manufactured by IPECO, CAGE K9075.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Upholstery material part number with letter suffix AY denotes part is made from leather, Material Code: CL 39, Color: Pacific Blue, material code per 1A001-1769AY. Part is manufactured by Bridge of Weir, CAGE U2472.

[5] Part identification is NG32/3, Special Application Foam (Brown). Specification Information per Benson Lund, CAGE KC174.

[6] Part identification is LD45FR. Specification information per Benson Lund Quality Dept. CAGE KC174.

Figure 5-8. Crew Seat Arm Assembly Cover and Foam (Sheet 2)

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REPAIR AND FABRICATION OF LIFE VEST STOWAGE COMPARTMENT

6.1. General.

A. This section contains the following procedures for repair and fabrication of life vest stowage compart-ment for the following Part Number(s):

Part Number Cage Code Noun, Description

103215-1 00679 Life Vest Stowage Compartment

B. Identify new life vest stowage compartment materials with the same part number and appropriate ma-terial specification.

C. Maintenance personnel should familiarize themselves with referenced drawings and specifications be-fore starting the fabrication process.

D. Review applicable drawings to identify which Standard Method drawings defined (ASTM, Fed-Std, etc.) are applicable. Standard Method drawings define the materials and process specification neces-sary to fabricate the desired part(s) or material(s).

E. Figure 6-1 contain the illustration of life vest stowage compartment configuration, providing the parts material descriptions and illustration references.

(1) Number on the index column assigned to the part in order to determine an exact location and allow cross referencing between illustration and text.

(2) Drawing/part number listed under this column is either assembly or part detail of the life vest stowage compartment assembly configuration.

(3) Description, Gage and Size column describe each life vest stowage compartment assembly or item.

It also contains the assigned nomenclature that appears in the title block of the engineering drawing, along with the modifiers and descriptive information to completely identify the item.

(4) Material or Make From column contains the description of the material, specification, and information used to fabricate the part.

(5) Reference column contains boxed letter assigned to curtain assembly configuration on text, to cross reference to illustration.

6.2. Check.

A. Examine assembly parts for wear, tear, obvious defects that could impair efficient life vest stowage compartment operation; fabricate life vest stowage compartment.

6.3. Repair.

A. Not Applicable.

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