oc-9 MAINTENANCE MANUAL GENERAL DESCRIPTION AND OPERATION - 1. Description A. ‘The instruments chapter describes and pictorially presents instrument and control panels that mount the instruments, switches, and indicators which are necessary for the operation of the airplane. Components which are specifically related to other systems are covered in text in the applicable chapter. Figure 1 identifies and shows the location of the major_panels. B. Independent instruments and unrelated systems are also included in this chapter. Separate, detailed coverage is provided for these components. ©. Maintenance consists mostly of replacement of instruments, control panels, switches, and panel components. All components are readily accessible and can be maintained without the use of special tools. Db. ‘The general maintenance practices section in this chapter shows examples of instrument attachments, main panel accesses, and control panel removals. Separate detailed removal coverage is not provided if a component is installed using standard attachments. Precautions and safety measures which must be observed before removal of components are also included in the general maintenance practices section. E. Most of the instruments are clamp mounted. A few are secured to the panel with screws. Electrical connections are made using miniature bayonet, quick-disconnect type connectors. Wiring to each instrument is of sufficient length to permit removal of the instruments from the face of the panel. F. All flexible instrument lines and fittings are of the replace- able type; nonkinking hose is used. Different size lines and fittings are installed to prevent inadvertent interchange of connections. The use of tees and crosses for connection to other instruments or instrument components is minimal. G. The accessibility to the main instrument panel and overhead panel components practically eliminates the requirement for complete removal of a panel fixture. The upper instrument and gusset panels consist of a one-piece frame assembly that is secured to structure and provides support for the captain's, first officer's, and center instrument panels. These three panels are attached to allow individual panel assemblies to slide aft and permit ready access to the forward side of the panels. Wiring and components on all main instrument panels are also accessible through the forward accessory compartment. Vibration isolation units are not used on the instrument panels. 31-00 CODE 1 Aug 1/66 Page 1UU uEAD AIKLKAP_UIVISION OCS MAINTENANCE MANUAL AFT OVERHEAD ‘Switch PANEL OVERHEAD cIRCUIT BREAKER PANEL i SREB ANEE HEA? ‘numerator Panel SGLARESHIELD PANEL UPPER INSTRUMENT PANEL LEFT CONSOLE FIRST OFFICER'S GUSSET PANEL FIRST OFFICER'S Ins TRUWENT conTROL WHEEL STRUME ‘CENTER INS TRUMENT conTROL, . PEDESTAL Pane. \ consoue 882-2198 33-00 Instrument and Control Panel Location CODE 1 Figure 1 Page 2 Aug 1/66DOUGLAS AIRCRAFT DIVISION oc-9 MAINTENANCE MANUAL H, ‘The overhead panels are installed in a contoured, bathtub- - shaped fixture which is attached to structure. Quick-release fasteners permit ready access to the separate panel assemblies and components. The forward overhead switch panel is hinged and weighs approximately 60 pounds. The overhead circuit. breaker panel is also hinged. Both it and the forward over~ head switch panel are provided with a safety latch which prevents the panel falling when the fasteners are released. Caution should be used to support the panels when the safety latches are released. ‘The annunciator panel and aft overhead switch panel are renovable. The individual system control Panels are attached with quick-action fasteners and use miniature bayonet quick-disconnect type connectors. 31-00 cope 1 aug 1/66 page 31 A. B. Ae Jul DOUGLAS AIRCRAFT DIVISION oC-s MMAINTENANCE MANUAL GENERAL _~_ MAINTENANCE PRACTICES - General Before performing instrument and control panel maintenance, applicable safety precautions should be selected in accordance with the work to be done. then replacing an instrument, switch or similar component, circuit breakers should be opened to deenergize the circuit. If work is performed adjacent to power system components on the overhead panels, external power must be removed and battery connections must be disconnected to deenergize the buses. An alternate method of removing all power from the overhead switch panel is to open the following circuit breakers: battery direct bus feed circuit breaker, battery ammeter circuit breaker, battery volt/ammeter circuit breaker, and the APU starter circuit breaker located on the battery circuit breaker panel, safety Precautions Remove Power from Circuit (2) Open applicable circuit breakers. (2) Install clamp BPV-5N (Burndy) ox P4-Siis (Nylon Molding Corporation) under circuit breaker button. (3) Tag circuit breakers with warning sign. WARNING: DO NOT CLOSE THIS CIRCUIT BREAKER. THIS CIRCUIT BREAKER MUST REMAIN OPEN UNTIL COMPLETION OF MAINTENANCE, Deenergize Power Buses (1) Disconnect external power. (2) Tag external power receptacle with warning sign. WARNING: DO NOT APPLY EXTERNAL POWER. Remove Power from Battery Bus (Q) Disconnect left battery connections (see Chapter 24). (2) Tag battery with warning sign. WARNING: DO NOT CONNECT BATTERY. 31-00 CODE 1 15/67 Page 201DOUGLAY AIRCKAH DIVISION oc-9 (MAINTENANCE MANUAL R 3. Energize circuits - R A. When work has been completed and panels are secured, perform R following steps. R (1) Close circuit breakers, connect battery connections, or R connect external power. R R (2) Remove warning signs. R - 31-00 CODE 1 Page 202 Jan 15/68DRR ADR RANMA AA WARD WH BD B wD OD DOUGLAS AIRCRAFT COMPANY oc-g MAINTENANCE MANUAL ENSTRUMENTS ~ GENERAL = MAINTENANCE PRACTICES - neral A. Instruments installed in the flight compartment have either round or square faces. Regardless of the shape of the instru- ment it is either clamp mounted or bezel mounted in the panel. Clamp mounted instruments have the clamp adjustment and clamp attachment screw heads accessible on the panel face (see Figure 201 view B or alternate view C). Bezel mounted instru- ments can have the screw heads accessible on the panel face (see Figure 201 view C) or the screws can mount from the back Side of the panel, such as on the cabin pressure controller. In either case, the entire panel must be opened for instrunent removal (see 31-02). B, Electrical connection to an instrument, regardless of shape or mounting method, is by rack and panel connection or pendant connection. See Figure 201 view alternate B for rack and panel electrical connection. See Figure 201 view B for pendant electrical connection. The maintenance practices following provide instrument removals installation instructions and procedures for cleaning instru- ment glass lenses. 2. Renovai/Installation Instruments (See Figure 201.) CAUT: DO NOT PRY INSTRUMENT FROM PANEL WITH SCREWDRIVER OR OTHER TOOL AS INSTRUMENT OR PANEL CAN BE DAMAGED. A. Remove Square Clamp Mounted Instrument (2) Open applicable system and lighting circuit breakers, WARNING: ‘TAG AND SAFETY CIRCOTT BREAKERS. (2) Support instrument and loosen clamp adjustment (instrument retaining) screws. NOTE: Clamp adjustment (instrument retaining) screws have a larger round head size than clamp attachnent. screws, however, in some cases clamp attachment screws will have a flat head. 31-01 CODE 10 Feb 15/70 Page 201DOUGLAS AIRCRAFT COMPANY oCc-9 MAINTENANCE MANUAL iRROR yore: ADJUST uipRor WARDWARE TO ALLOW ROTATIONAL MOVEMENT OF MIRROR, GLARESMIELD, CLAMP ADJUSTHENT ‘SCREW cuauP HOSE CONNECTION SN posimiouins AG DeTENT aes oy Ze eS ‘ATTACHMENT ‘SCREW PENDENT ELECTRICAL CONNECTION | ROUND INSTRUMENT CLAMP MOUNTED {TYPICAL INSTALLATION SWITCH, LIGHT, AND MIRROR TYPICAL INSTALLATION view B cap views en2-t784a R 31-02 Instrument Typical Installation R CODE 10 Figure 201 (sheet 1) Page 202 Feb 15/70DOUGLAS AIRCRAFT COMPANY oc-g MAINTENANCE MANUAL SENSI sy . Sie vow a new € sytem ce ~ SSavee tion EW AL A STALOATION e02.9128 R Instrument Typical Installation 31-01 R Figure 201 {Sheet 2) CODE 10 Feb 15/70 Page 202ABR RW RAD AAD DB DRAW was a) DARN Sm BRD we @ a ) (6) a (8) ) DOUGLAS AIRCRAFT COMPANY oc-g MAINTENANCE MANUAL Press clamp adjustment screws in until flush with panel to release clamp fressure on instrument. Loosen clamp attachment screws as necessary to relieve tension. For rack and panel type electrical connection instrument maintain pressure on perimeter of instrument and allow it to eject slowly from panel until spring tension of spring- loaded electrical connector is relieved. Carefully remove instrument from panel. CAUTION: DO NOT ROTATE SPRING-LOADED RACK AND PANEL ELECTRICAL CONNECTED INSTRUMENTS AS ROTATION WILL DAMAGE TRE ELECTRICAL CONNECTOR. For pendant type electrical connection instrument carefully pull instrument from panel and disconnect electrical con- hector at back of instrument. When removing instruments having tubing connections tip instrument out of panel for access to tubing disconnect. cap or plug instrument electrical connector and tubing ports. 3, Remove Round Clamp Mounted Instrument a ey @) w open applicable system and lighting circuit breakers. WARNING: ‘TAG AND SAFETY CIRCUIT BREAKERS. Support instrument and loosen clamp adjustment (instrument retaining) screw. NOTE: Clamp adjustment (instrument retaining) screws have a larger round head size than clamp attachment screws, however, in some cases clamp attachment screws will have a flat head. Loosen clamp attachment screws as necessary to relieve ‘tension. For rack and panel type electrical connection instrument maintain pressure on perimeter of instrument and allow it to eject slowly from panel until spring tension of spring- loaded electrical connector is relieved. 31-01 copz 10 Page 2028 Feb 15/70wan wm 7 WD A Be we PHD aww D DP BYRD Y AMR WORD ) (6) a) 8) DOUGLAS AIRCRAFT COMPANY oc-g9 MAINTENANCE MANUAL Carefully remove instrument from panel. - CAUTION: DO NOT ROTATE SPRING~LOADED RACK AND PANEL ELECTRICAL CONNECTED INSTRUMENTS AS ROTATION WILL DAMAGE THE ELECTRICAL CONNECTOR. For pendant type electrical connection instrument carefully pull instrument from panel and disconnect electrical con- nector at hack of instrument. When removing instruments having tubing connections tip instrument out of panel for access to tubing disconnect. cap or plug instrument electrical connector and tubing ports. ¢. Install Square or Round Clamp Mounted Instrument a) @) Q 4) 6) 6) mam (8) Feb 15/70 check applicable circuit breakers are open and tagged. Remove caps and plugs from connectors. Connect tubing lines (if any) and tighten to torque specified in Figure 202. For pendant type electrical connection instruments connect electrical connector and position instrument in clamp in instrument panel. For rack and panel type electrical connection instruments insert instrument through clamp and panel carefully mating electrical connection and maintain pressure against spring- loaded electrical connector. CABTION: DO NOT ROTATE SPRING-LOADED RACK AND PANEL ELECTRICAL CONNECTED INSTRUMENTS AS ROTATION WILL DAMAGE THE ELECTRICAL CONNECTOR. Secure clamp attachment screws. NOTE: Clamp adjustment (instrument retaining) screws have a larger round head size than clamp attachment screws, however, in sone cases clamp attachment screws will have a flat head. Secure clamp adjustment (instrument retaining) screws. Check operation of instrument. 31-02 ‘CODE 10 Page 202Cnaa oe-9 MAINTENANCE MANUAL STANDARD TORQUE VALUE FOR ANGL8 B-NUTS ' Torque valve (Inch-pounds) ' 1 ' ‘ ( 1 - { Benut | Aluminum t steel Size | Hex t ' 1 Size ote a ! 1 1 { ! 1 1 { Standard { Oxygen [ Standard | Firex { ' 1 1 t U ' oto + +: + +: ‘ ‘ { ' 1 1 t toe of 378 | Ins ft 1 35-45 ( 103716 1 «7716 | (285 | 1200) ! t 1 ow | 9716 4 50 1 50-75 | 150 { 1 1 S716 1 5/78 | 78 1 100-125 [| 200 ( 1 1 378 | avis 12 1 200-250 | 300 ' 1 1 92 | 778 4 200 {300-400 | 500 1 500 | 1 5/78 41 {312 1 900-450 4 700 1 500 1 1 378 [1 we 4 450 1 500-550 | 1000 1 500 | in {1 172 4 600 | 700-750 ] 1400-1500] 1300 | pia 12 1 750 ' 1 3400 {1700 | pLas2 42 14 4900 1 1 a4o0 12100 t 11374 {2 578 f 1050 I ' 12500 | 12 12 7/8 | 1200 1 {5500 1 2900 5 t ' ' ' t 1 ' ' 1 | ROTE: Tighten ANSL8 B-nuts to the above values, using the 1 t torgue based on the tube material regardless of fitting | 1 or nut material. See Chapter 20 for detailed torque = | 1 information. t t t Torque Value Chart Figure 202 31-02 CODE 10 Nov 1/68 Page 203Ae Dy gE. DOUGLAS AIRCRAFT DIVISION oc-g9 MAINTENANCE MANUAL Cleaning_Instrument_glass_Lenses - All instrument glass lenses should be cleaned at frequent intervals. Whenever instruments with glass lenses are handled, precautionary cleaning should be performed as fingerprint per- spiration may permanently etch glass surfaces. Cleaning may be accomplished by using a commercial: liquid detergent or a solvent such as isopropyl alcohcl or acetone. If solvent is used, care should be taken to insure compati- bility of the instrument mounting finish with the solvent. CAUTION: SOLVENTS ARE FLAMMABLE AND SHOULD BE USED ONLY IN WELL VENTILATED AREAS AWAY FROM OPEN FLAME. Prior to applying cleaning solution to lens surfaces, ali loose dust should be blown off with clean, dry air. A clean soft cloth must be used for both cleaning and drying. The cleaning process can cause static electricity to build up in the lens. Each glass lens should be touched gently with a metallic object held in the hand to insure dissipation of any possible static charge. Cleaning Lenses (1) Prepare cleaning sclution according to manufacturer's directions. (2) Apply small amount of solution to lens. (3) Apply clean rinse water. () Wipe lens dry immediately. NOTE: Failure to wipe lens dry immediately may result in a stain which could permanently damage lens surface. 31-01 CODE 10 Page 204 Jan 15/68DOUGLAS AIRCRAFT DIVISION oCc-9 MAINTENANCE MANUAL INSTRUMENT _BANELS_-_GEWERAL - MAINTENANCE PRACTICES - 1. General A. The following instructions concern the removal/installation of the captain's, first officer's, and center instrument panels. 2. Removal/Installation Instrument Panels - A. Remove Captain's/First Officer's Panel ay @) @ @ 5) {6) Open applicable circuit breakers. Secure control column in full aft position. Release rudder pedal adjuster guide to avoid damage to guide and control knob. CAUTION: RUDDER PEDAL ADJUSTER GUIDE ASSEMBLY SHOULD BE RELEASED PRIOR TO OPENING OR REMOVING PANELS TO AVOIL LAMAGE TO GUIDE AND CONTROL KNOB. Loosen fasteners securing panel to frame and tilt panel down. Disconnect all electrical connections and lines from panel. Lift panel up to displace panel bar assembly from frame. NOE: The lifting motion shifts the pivot and displaces the bar assembly from the frame. B, Install captain's/First Officerts Panel a) 2) G «@) 6) (6) om Check that applicable circuit breakers are open. Position panel bar assembly in frame and leave panel tilted down. Connect all electrical connections and lines. Tighten lines to specified torque (see 31-01). Tilt panel up and secure fasteners. Secure rudder pedal adjuster guide. Release control column. Close circuit breakers and remove warning signs. 31-02 CODE 2 Jan 15/68 Page 201DOUGLAS AIRCRAFT DIVISION oc-g MAINTENANCE MANUAL C. Remove Center Instrument Panel - ay @) ) ay 3) open applicable circuit breakers. Open fire extinguisher control circuit breakers and rotate fire extinquisher handles to clear center instrument panel. CAUTION: TO PREVENT DISCHARGE OF BOTTLES CIRCUIT MUST BE DEENERGIZED AND HANDLES ROTATED PRIOR TO REMOVAL OF PANEL. - Loosen fasteners and slide panel aft. Disconnect all electrical connections and lines from panel. Remove panel by pulling directly aft. Keep panel on plane perpendicular to frame so detent clears guide spacers. D, Install Center Instrument Panel a 2) i) cay ©) 31-02 CODE 1 R Page 202 check that applicable circuit breakers and fire extinguisher control circuit breakers are open. Hold panel on plane perpendicular to frame and slide into position. Connect electrical connections and lines to panel. Tighten lines to specified torque (see 31-01). Prior to securing panel, check that landing gear anti- retraction lever is properly positioned through panel opening. NOE: Failure to properly position landing gear anti- xetraction lever could prevent retraction of the gear. Secure panel. Aug 1768oc-9 MAINTENANCE MANUAL —— as et capTAIN's iS TRUMENT PANEL centeR stRUMENT SS Panel ww Figs orricen's RISTRUMIENT PANEL ube, SPACER FRAME berewT ‘ASSEMBLY vEw A NOTE: TOREMOVE, KEEP PANEL ON PLANE PERPENDICULAR TO FRANE SO DETENT CLEARS GUIDE SPACER. aR MOVE, LIFT PANEL TO SHIFT ASSENGLY PIVOT AMD 6ISPLACE BAR ASSEMBLY FROM FRAME, we2-200 Instrument Panels 31-02 Figure 201 cone 1 Jan 15/68 Page 203wa ONE RM Oe x (6) a) (8) 49) (10) 31-02 CODE 1 Page 204 DOUGLAS AIRCRAFT DIVISION oc-F MAINTENANCE MANUAL Depressurize main hydraulic system (see Chapter 29). - caur. MAKE CERTAIN LANDING GEAR GROUND LOCKPINS ARE INSTALLED PRIOR TO DEPRESSURIZATION, Move landing gear control lever to retract and extend positions. Movement should be smooth and free of interference. Making certain landing gear control lever is in extend position, pressurize main hydraulic system (see Chapter 29). Reposition fire extinguisher handles. Close circuit breakers and remove warning signs. Aug 1/68