cmm25 66 07

To: Holders of 737-300/400/500 Aircraft Slide Evacuation System
(P/N 61621-469, manufactured by Air Cruisers) Component Maintenance

Manual 25-66-07.
Revision No. 12, Dated 13 Nov 2015
HIGHLIGHTS
Revision No. 12 of Component Maintenance Manual 25-66-07 reflects pages

which have been revised, added, or deleted. The revisions are outlined below.
Please discard the manual now in your possession, replace with the attached
revised manual, and enter your initials for Revision No. 12 dated 13 Nov 2015 to
the Record of Revisions.
CHAPTER/SECTION
DESCRIPTION OF CHANGE
PAGE NUMBER
DOCUMENT ENTIRETY
(where applicable) Updated company logo throughout. “Zodiac Aero
Evacuation Systems” or “ZAES” was “Air Cruis-
ers”; “Air Cruisers” was “Air Cruisers Company”;
“Dow Corning Molykote” was “Dow Corning 55M”
or “Dow Corning Molykote 55” (where applicable).
Additional updates listed below.
TITLE PAGE
T-1 Updated export statement per current ZAES
guidelines; added “Manufactured by Air Cruisers”;
updated revision, date, and copyright date.
RECORD OF REVISIONS
RR-1 Added Revision 12.
HIGHLIGHTS
25-66-07 Page 1 of 4
CHAPTER/SECTION
PAGE NUMBER
SERVICE INFORMATION
LETTER RECORD
SIL-1 and SIL-2 S.I.L.s 25-113, 25-160, 25-166 and 25-199: cor-
rected titles.
LIST OF
EFFECTIVE PAGES
LEP-1 through LEP-4 Updated to reflect this revision.
INTRODUCTION
INTRO-9 Paragraphs 8.B.(2).(d) and (e): added “in infla-
tion...”.
TESTING AND
FAULT ISOLATION
113 Added CAUTION (per current ZAES guidelines).
124 Paragraph 3.I: replaced comma with “and”.
130 Figure 113: “114” was “113”.
DISASSEMBLY
308 Paragraph 3.F: “320, 320A” was “190A” (ref. ECN
25-66-07, Rev. 11a).
322 Paragraph 11.B: “counter-clockwise” was “to the
left”.
CHECK
503 Table 501: deleted “replace slide or” (per current
ZAES guidelines).
HIGHLIGHTS
25-66-07 Page 2 of 4
CHAPTER/SECTION
PAGE NUMBER
REPAIR
604 Table 603: deleted “M11787 or” (ref. ZAES Stan-
dard Practice #6).
609 Paragraph 2.E.(1): deleted “M11787 or” (ref.
ZAES Standard Practice #6).
615 Paragraph 3.B: added metric equivalent.
628 Figure 616: “Fabric” was “Girt”.
629 Figure 617: added “Top” (previously omitted).
634 Paragraph 8.I: added metric equivalent.
635 First and second NOTEs relocated (corrections).
ASSEMBLY
708 Paragraph 6.C: “alignment mark” was “arrow
stencilled”; Figure 705: “alignment” was “triangu-
lar”.
ILLUSTRATED PARTS
LIST
1008 and 1009 Table 1001: updated Vendor criteria.
1011 through 1013 Updated numeric index to reflect this revision.
1016 IPL Figure 1: “320, 320A” was “190A” (ref. ECN
25-66-07, Rev. 11a).
1019 Items 20 and 30: Air Cruisers part numbers now
listed under part number column and equivalent
vendor part number now listed under Nomencla-
ture column per A4A iSpec 2200 requirements.
1021 and 1022 Table text relocation due to updates. Additional
updates listed below.
1021 Items 190 and 190A: deleted (ref. ECN 25-66-07,
Rev. 11a).
HIGHLIGHTS
25-66-07 Page 3 of 4
CHAPTER/SECTION
PAGE NUMBER
ILLUSTRATED PARTS
LIST (Cont’d)
1022 Item 215: newly added (previously omitted); Items
220 and 220A Nomenclature: corrected indenture
system.
1023 Items 320, 320A, 330 and 340: newly added (ref.
ECN 25-66-07, Rev. 11a).
HIGHLIGHTS
25-66-07 Page 4 of 4
737-300/400/500 AIRCRAFT
AFT DOOR
EVACUATION SLIDE
MANUFACTURED BY AIR CRUISERS
ACC P/N 61621-469

BOEING P/N 10-61323-469
COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST
The end item product(s)/commodity(s) described in the Component Maintenance Manual
(CMM) is controlled for export under the jurisdiction of the United States Department of Com-
merce, Bureau of Industry and Security Export Administration Regulation (EAR). Zodiac Aero
Evacuation Systems (ZAES) believes the proper Export Control Classification Number (ECCN)
for the described product is 9A991. This CMM is also subject to the EAR. ZAES believes the
proper ECCN for this CMM is 9E991. An export license may be required before this technology
(CMM) is used for development, production, or use by foreign persons from specific coun-
tries. The user of this technology (CMM) has the individual responsibility to abide by all U.S.
export laws and regulations.
ORIGINAL ISSUE: 22 JULY 1991

REVISION NO. 12 DATED: 13 NOV 2015
Zodiac Aero Evacuation Systems, Copyright 2015
T-1
25-66-07
61621
RECORD OF REVISIONS
RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. UPON

RECEIPT OF A REVISION, INSERT THE REVISED PAGES INTO
THE MANUAL, AND ENTER THE DATE INSERTED, AND YOUR INI-
TIALS.
REVISION REVISION ENGINEER WRITERS DATE

INITIALS
NO. DATE INITIALS INITIALS INSERTED
1 30 Apr 1992
2 16 Dec 1996 DHS
3 20 Oct 2000 DHS JD
4 14 Mar 2003 DHS DV
5 10 Oct 2003 EHS DV
6 19 Aug 2005 JOD MLS
7 28 Jun 2007 JOD MLS
8 13 Mar 2009 TJ MLS
9 12 Feb 2010 TJ MLS
10 13 Apr 2012 MKT MLS
11 1 Aug 2014 DDO MLS
12 13 Nov 2015 MKT MLS
RR-1
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TEMPORARY REVISION RECORD
DATE INSERTED REMOVED

TEMP. ISSUE
INCORPORATED
REV. NO. DATE
INTO CMM DATE BY DATE BY
TR25-1 9 Feb 1994 16 Dec 1996
TR-1
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SERVICE BULLETIN RECORD
SERVICE BULLETIN / DATE

ISSUE DATE TITLE
REVISION NUMBER INCORPORATED
103-25-28 4 Dec 1998 13 Apr 2012 Optional Installation of Gage Posi-

tioner
737 103-25-31 / R1 31 Jan 2003 14 Mar 2003 Optional Relief Valve Replacement
737 103-25-32 25 Jul 2001 13 Apr 2012 Optional Chafing Patch Installation
on Detachable Girt Assembly
737 103-25-38 11 Oct 2002 13 Apr 2012 Seam Inspection/Repair
SB-1
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SERVICE INFORMATION LETTER RECORD
SERVICE
INFORMATION DATE
ISSUE DATE SUBJECT
LETTER / REVISION INCORPORATED
NUMBER
25-82 / R5 16 Oct 2001 14 Mar 2003 Recommended Hydrostatic Test

Intervals Inflation Hose Assemblies
25-85 6 May 1991 28 Jun 2007 B737 Evacuation System, Pressure

Indicator Transients
25-92 5 Nov 1993 14 Mar 2003 Seam Wicking
25-98 / R5 12 Nov 2007 13 Mar 2009 Maintenance Interval Recommen-

dation
25-102 / R26 31 Jan 2014 1 Aug 2014 Authorized Repair/Service Facilities
25-113 / R1 12 Nov 1999 14 Mar 2003 Instructions for Replacing an Indi-

vidual Lamp Housing on an Exist-
ing Lamp Harness
25-131 25 Jun 1999 14 Mar 2003 737 Evacuation Slide Floor Run
Functional Test
25-140 / R1 29 Nov 2000 28 Jun 2007 Implementation of Carbon Reser-

voirs
25-152 2 Mar 2001 14 Mar 2003 Improved Heat Reflective Coating

Compound
25-160 / R1 20 Jun 2003 10 Oct 2003 Use of Teflon Tape as a Sealant on

Pipe Threads Only
25-161 8 May 2002 10 Oct 2003 Shelf Life for P/N B14056-Series
Ethylene Propylene O-Rings
25-166 / R1 5 Dec 2002 14 Mar 2003 Light System Test Unit: Approval of
BaseWest Model TS-420 as an
Acceptable Alternative to DME Cor-
poration Model TU-14
25-181 / R11 12 Apr 2013 1 Aug 2014 Implementation of New Valve/Reg-

ulator Fitting
25-183 / R1 2 Nov 2004 28 Jun 2007 Implementation of New Reservoir

and Valve Assemblies
SIL-1
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SERVICE
INFORMATION DATE
ISSUE DATE SUBJECT
LETTER / REVISION INCORPORATED
NUMBER
25-193 / R1 24 Nov 2004 28 Jun 2007 Pentabromodiphenyl and Octabro-

modiphenyl Ether
25-199 15 Dec 2004 28 Jun 2007 Hydrostatic Test Machine, TO4853,

for Testing Hose Assemblies
25-210 20 Mar 2006 28 Jun 2007 Spare Adhesive Nomenclature and

Packaging
25-211 20 Mar 2006 28 Jun 2007 Maintenance Release Record

Alteration
25-222 / R3 4 Nov 2011 13 Apr 2012 Methodolgy of Serial Numbers
25-228 / R2 4 Aug 2008 13 Mar 2009 Hose Assembly Product Improve-

ment
25-243 29 May 2009 12 Feb 2010 Inside Coating of Evacuation Sys-

tems, Non OEM Approved Repair
Procedure
25-244 3 Aug 2009 12 Feb 2010 Change of Address
25-252 / R1 14 May 2010 13 Apr 2012 Replacement of Fire Retardant

Tape
SIL-2
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LIST OF EFFECTIVE PAGES SECTION PAGE DATE

SECTION PAGE DATE
Introduction INTRO-8 13 Nov 2015
Title Page T-1 13 Nov 2015 (Cont’d) INTRO-9 13 Nov 2015
INTRO-10 Blank
Record of RR-1 13 Nov 2015
Revisions Description 1 13 Nov 2015
and 2 13 Nov 2015
Operation 3 13 Nov 2015
Temporary TR-1 13 Nov 2015
Revision 4 13 Nov 2015
Record 5 13 Nov 2015
6 13 Nov 2015
Service SB-1 13 Nov 2015 7 13 Nov 2015
Bulletin 8 13 Nov 2015
Record 9 13 Nov 2015
10 Blank
Service Infor- SIL-1 13 Nov 2015
mation Let- SIL-2 13 Nov 2015
Testing and 101 13 Nov 2015
ter Record
Fault 102 13 Nov 2015
Isolation 103 13 Nov 2015
List of LEP-1 13 Nov 2015 104 13 Nov 2015
Effective LEP-2 13 Nov 2015
105 13 Nov 2015
Pages LEP-3 13 Nov 2015
106 13 Nov 2015
LEP-4 13 Nov 2015
107 13 Nov 2015
108 13 Nov 2015
Table of T/C-1 13 Nov 2015
Contents 109 13 Nov 2015
110 13 Nov 2015
Introduction INTRO-1 13 Nov 2015 111 13 Nov 2015
INTRO-2 13 Nov 2015 112 13 Nov 2015
INTRO-3 13 Nov 2015 113 13 Nov 2015
INTRO-4 13 Nov 2015 114 13 Nov 2015
INTRO-5 13 Nov 2015 115 13 Nov 2015
INTRO-6 13 Nov 2015 116 13 Nov 2015
INTRO-7 13 Nov 2015 117 13 Nov 2015
LEP-1
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SECTION PAGE DATE SECTION PAGE DATE
Testing and 118 13 Nov 2015 Disassembly 315 13 Nov 2015

Fault 119 13 Nov 2015 (Cont’d) 316 13 Nov 2015
Isolation 120 13 Nov 2015 317 13 Nov 2015
(Cont’d) 121 13 Nov 2015 318 13 Nov 2015
122 13 Nov 2015 319 13 Nov 2015
123 13 Nov 2015 320 13 Nov 2015
124 13 Nov 2015 321 13 Nov 2015
125 13 Nov 2015 322 13 Nov 2015
126 13 Nov 2015 323 13 Nov 2015
127 13 Nov 2015 324 13 Nov 2015
128 13 Nov 2015
129 13 Nov 2015 Cleaning 401 13 Nov 2015
130 13 Nov 2015 402 13 Nov 2015
131 13 Nov 2015 403 13 Nov 2015
132 13 Nov 2015 404 13 Nov 2015
133 13 Nov 2015 405 13 Nov 2015
134 Blank 406 13 Nov 2015
Disassembly 301 13 Nov 2015 Check 501 13 Nov 2015

302 13 Nov 2015 502 13 Nov 2015
303 13 Nov 2015 503 13 Nov 2015
304 13 Nov 2015 504 13 Nov 2015
305 13 Nov 2015 505 13 Nov 2015
306 13 Nov 2015 506 13 Nov 2015
307 13 Nov 2015 507 13 Nov 2015
308 13 Nov 2015 508 13 Nov 2015
309 13 Nov 2015 509 13 Nov 2015
310 13 Nov 2015 510 13 Nov 2015
311 13 Nov 2015 511 13 Nov 2015
312 13 Nov 2015 512 13 Nov 2015
313 13 Nov 2015 513 13 Nov 2015
314 13 Nov 2015 514 Blank
LEP-2
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Repair 601 13 Nov 2015 Repair 632 13 Nov 2015

602 13 Nov 2015 (Cont’d) 633 13 Nov 2015
603 13 Nov 2015 634 13 Nov 2015
604 13 Nov 2015 635 13 Nov 2015
605 13 Nov 2015 636 13 Nov 2015
606 13 Nov 2015 637 13 Nov 2015
607 13 Nov 2015 638 13 Nov 2015
608 13 Nov 2015 639 13 Nov 2015
609 13 Nov 2015 640 13 Nov 2015
610 13 Nov 2015 641 13 Nov 2015
611 13 Nov 2015 642 13 Nov 2015
612 13 Nov 2015 643 13 Nov 2015
613 13 Nov 2015 644 13 Nov 2015
614 13 Nov 2015 645 13 Nov 2015
615 13 Nov 2015 646 13 Nov 2015
616 13 Nov 2015 647 13 Nov 2015
617 13 Nov 2015 648 13 Nov 2015
618 13 Nov 2015 649 13 Nov 2015
619 13 Nov 2015 650 13 Nov 2015
620 13 Nov 2015 651 13 Nov 2015
621 13 Nov 2015 652 13 Nov 2015
622 13 Nov 2015 653 13 Nov 2015
623 13 Nov 2015 654 13 Nov 2015
624 13 Nov 2015 655 13 Nov 2015
625 13 Nov 2015 656 13 Nov 2015
626 13 Nov 2015 657 13 Nov 2015
627 13 Nov 2015 658 13 Nov 2015
628 13 Nov 2015 659 13 Nov 2015
629 13 Nov 2015 660 13 Nov 2015
630 13 Nov 2015 661 13 Nov 2015
631 13 Nov 2015 662 13 Nov 2015
663 13 Nov 2015
LEP-3
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Repair 664 13 Nov 2015 Special Tools 911 13 Nov 2015

(Cont’d) 665 13 Nov 2015 Fixtures and 912 13 Nov 2015
666 13 Nov 2015 Equipment 913 13 Nov 2015
914 Blank
Assembly 701 13 Nov 2015
702 13 Nov 2015 Illustrated 1001 13 Nov 2015
703 13 Nov 2015 Parts List 1002 13 Nov 2015
704 13 Nov 2015 1003 13 Nov 2015
705 13 Nov 2015 1004 13 Nov 2015
706 13 Nov 2015 1005 13 Nov 2015
707 13 Nov 2015 1006 13 Nov 2015
708 13 Nov 2015 1007 13 Nov 2015
709 13 Nov 2015 1008 13 Nov 2015
710 13 Nov 2015 1009 13 Nov 2015
711 13 Nov 2015 1010 13 Nov 2015
712 13 Nov 2015 1011 13 Nov 2015
1012 13 Nov 2015
Fits and 801 13 Nov 2015 1013 13 Nov 2015
Clearances 802 13 Nov 2015 1014 13 Nov 2015
803 13 Nov 2015 1015 13 Nov 2015
804 Blank 1016 13 Nov 2015
1017 13 Nov 2015
Special 901 13 Nov 2015 1018 13 Nov 2015
Tools, 902 13 Nov 2015 1019 13 Nov 2015
Fixtures and 903 13 Nov 2015 1020 13 Nov 2015
Equipment 904 13 Nov 2015
1021 13 Nov 2015
905 13 Nov 2015
1022 13 Nov 2015
906 13 Nov 2015
1023 13 Nov 2015
907 13 Nov 2015
1024 Blank
908 13 Nov 2015
909 13 Nov 2015
Folding APPX-1 13 Nov 2015
910 13 Nov 2015
Procedure Appendices
LEP-4
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TABLE OF CONTENTS
Page
INTRODUCTION INTRO-1
DESCRIPTION AND OPERATION 1
TESTING AND FAULT ISOLATION 101
DISASSEMBLY 301
CLEANING 401
CHECK 501
REPAIR 601
ASSEMBLY 701
FITS AND CLEARANCES 801
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 901
ILLUSTRATED PARTS LIST 1001
FOLDING PROCEDURE APPENDICES APPX-1
T/C-1
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TABLE OF CONTENTS
INTRODUCTION
Page
1. General Information INTRO-2
2. Document Distribution INTRO-3
3. Qualification Dates INTRO-3
4. Abbreviations and Symbols INTRO-4
5. Listing of Authorized Service Centers INTRO-7
6. Identifying Revised Material INTRO-7
7. Maintenance Inspection Log/Maintenance Release Record INTRO-7
8. Summary of Zodiac Aero Evacuation Systems Maintenance
Recommendations INTRO-8
INTRO-1
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1. General Information
A. This manual provides Description, Operation, Disassembly, Assembly,

Repair, and Testing Instructions for approved mechanics, and an Illus-
trated Parts List for the 737-300/400/500 Aft Door Lightweight Aircraft
Evacuation Slide Assemblies listed in Table 1 and Illustrated in Figures
1 through 3 of the Description and Operation section. The equipment is
manufactured by Air Cruisers, 1747 State Route 34, Wall Township, NJ
07727-3935, United States of America - CAGE Code 70167.
B. To facilitate use of this manual, data that is particular to a specific con-
figuration(s) is presented separately by subsection within each major
section of the manual. The Table of Contents at the beginning of the
manual tabulates all major sections. A more detailed Table of Contents
is provided at the beginning of each section.
C. Throughout the manual pay particular attention to the WARNINGS,
CAUTIONS, and NOTES; their intentions are as follows:
WARNING: TO CALL ATTENTION TO METHODS AND PROCE-
DURES WHICH MUST BE FOLLOWED PRECISELY TO
AVOID INJURY TO PERSONS.
CAUTION: TO CALL ATTENTION TO METHODS AND PROCE-
DURES WHICH MUST BE FOLLOWED TO AVOID DAM-
AGE TO EQUIPMENT.
NOTE: To call attention to methods which make the job easier.
D. Pages INTRO-4, INTRO-5, and INTRO-6 consist of a list of Abbrevia-
tions and Symbols used throughout this manual.
E. Comments, suggestions, or improvements to this document, including
those of an editorial nature, can be sent to:
Zodiac Aero Evacuation Systems

Technical Publications Department,
1747 State Route 34, Wall Township, NJ 07727-3935
Tel. (732) 681-3527, Fax. (732) 681-9163
E-mail: ZAESTechPubs@zodiacaerospace.com
www.zodiacaerospace.com
INTRO-2
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2. Document Distribution
A. Copies of non restricted Component Maintenance Manuals (CMM),
Service Bulletins (SB), Service Information Letters (SIL), and Folding
Procedures are available on the Technical Publications Index (TPI)
through Zodiac Services website:
http://tpi.services.zodiacaerospace.com/technical/tpi
The documents will be in PDF format and can be read on-line or down-
loaded at the customer's convenience.
To subscribe for this service, contact Zodiac Services using link:
http://tpi.services.zodiacaerospace.com/subscribe/form
For additional information, please visit:
www.services.zodiacaerospace.com
3. Qualification Dates:
VERIFICATION DATE
Testing and Fault Isolation 22 July 1991

Disassembly 22 July 1991
Assembly 22 July 1991
A. Refer to Zodiac Aero Evacuation Systems (ZAES) Component Mainte-

nance Manual 25-65-20 for maintenance of Reservoir and Valve/Regu-
lator Inflation Assembly. Listed below is a cross reference tabulation
between the Evacuation Slide Assembly and the Reservoir and Valve/
Regulator Assembly.
RESERVOIR
AND
EVACUATION
AIRCRAFT DOOR FOLDING VALVE/ INFLATION
SLIDE
DESIGNATION PROCEDURE REGULATOR CMM
P/N
ASSEMBLY
P/N
Aft Door (Automatic 61621-469 P-11990 61768-101 25-65-20

Inflation) 61768-201
INTRO-3
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4. Abbreviations and Symbols
AD Airworthiness Directive
AR As Required
Assy. Assembly
Approx. Approximate
@ At
BKDN Breakdown
cc Cubic Centimeters
CFE Customer Furnished Equipment
CFM Customer Furnished Material
CFR Code of Federal Regulations
CGA Compressed Gas Association
CL Centerline
cm Centimeter
CMM Component Maintenance Manual
Cont’d Continued
CO2 Carbon Dioxide
Csk. Countersunk
Cu. Ft. Cubic Feet
Cu. In. Cubic Inch
DCR Document Change Request
Dia. Diameter
DOT Department of Transportation
ECN Engineering Change Notice
EFF Effectivity
ELT Emergency Locator Transmitter
etc. Etcetera
o
C Degrees Centigrade
o
F Degrees Fahrenheit
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
FIG. Figure
Ft. Feet, Foot
Ft. Lb. Foot Pounds
g Gram
Hg Mercury
ICC Interstate Commerce Commission
INTRO-4
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I. D. Inside Diameter
In. Inch
In. Hg Inches of Mercury
In. Lb. Inch Pounds
IPL Illustrated Parts List
kg Kilograms
kg/Sec Kilograms per Second
Lb. Pound or Pounds
Lb./Sec Pounds per Second
L. H. Left Hand
L. S. Left Side
m Meter
Max. Maximum
MEK Methyl Ethyl Ketone
Min. Minimum
MIL STD Military Standard
mm Millimeter
mm Hg Millimeter of Mercury
MS Military Standard
N Newton
N/A Not Applicable
N/cm2 Newtons per Square Centimeter
N-m Newton-Meter
NAS National Aircraft Standard
NHA Next Higher Assembly
NO. Number
NP Not Procurable
O. D. Outside Diameter
P/N Part Number
Para. Paragraph
PERM Permanent
Post Subsequent to
Pre Prior to
psig Pounds per Square Inch Gage
QTY Quantity
R Revised
Rd. Hd. Round Head
REE Rejection Elastic Expansion
INTRO-5
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REV Revision
RF or REF. Reference
R. H. Right Hand
R. S. Right Side
S. B. (SB) Service Bulletin
SCFM Standard Cubic Feet per Minute
Sec. Seconds
S. I. L. (SIL) Service Information Letter
S/N Serial Number
SRB Survival Radio Beacon
Subs Subsequent
Supsd Superseded
Supsds Supersedes
Temp. Rev. or T. R. Temporary Revision
TSO Technical Standard Order
Ty. Type
TYP. Typical
V Vendor
*** Denotes end of Attaching Hardware
- Denotes Item Not Illustrated
 Denotes Intentionally Left Blank
INTRO-6
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5. Listing of Authorized Service Centers
For a complete list of authorized service centers refer to S. I. L. 25-102.
6. Identifying Revised Material
NOTE: A revision to a page is defined as any change to the printed

matter that existed previously.
A. Revisions, additions, and deletions shall be identified by a vertical
black line along the left hand margin of the page opposite only that por-
tion of the printed matter that has changed.
B. A black line in the left hand margin opposite the page number and date,
will indicate that the text was unchanged but the material was relocated
to a different page.
C. For the detailed parts list listing an individual code letter “R”, instead of
a vertical black line, shall be used on each line to identify revisions.
D. Each page of a complete manual change is assigned the new revision
date.
7. Maintenance Inspection Log/Maintenance Release Record
A. A maintenance inspection log/record is shipped with each system and

is generally located in a maintenance pocket on the outside of a carry-
ing case, lacing cover, container, and/or between a girt assembly
depending on the system configuration. It is recommended that the
inspection log/record be kept with the system at all times.
NOTE: It is recommended that indelible ink be used for recording.
The inspection log/record is for the recording of both scheduled and
non-scheduled maintenance that has been performed. This information
is vital to personnel performing maintenance and/or incorporation of
service bulletins.
INTRO-7
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8. Summary of Zodiac Aero Evacuation Systems Maintenance Recommendations
A. For Evacuation Systems perform the following every 3 years up to and

including 15 years**. After system has been in service for more than 15
years the following should be done each year (annually), if the inflat-
able and hose are not replaced at 15 years*.
RECOMMENDATION REFERENCE
(1). Functional Deployment Test See Testing section.
(2). Inflatable Integrity Verifica- See Testing section.
tion Tests
(a). Perform Overpressure
Test (If applicable)*
(b). Perform Leakage Test
(If applicable)*
(3). Hose Integrity Verification See Testing section.
(If applicable)*
(4). Light System Test See Testing section.
(If applicable)*
(5). Disassemble System to the See Disassembly and Check sections.
extent necessary to comply
with Check section.
(6). Verify incorporation of all Technical Publication Index (TPI) avail-
outstanding Service Bulle- able through Zodiac Services website:
tins and Service Information http://tpi.services.zodiacaerospace.com/
Letters. technical/tpi
Refer to Introduction section (Para. 2) of
this CMM.
* If the inflatable, hose, and applicable life-limited items are replaced at

15 years, then the standard 3 year maintenance interval is re-instated for the
next 15 years.
** The first maintenance shall be performed three years from the evacuation
system’s date of manufacture. Subsequent maintenance shall be performed
three years from the prior maintenance date, up to and including 15 years.
INTRO-8
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B. For Inflation Systems perform the following every three years**.
RECOMMENDATION REFERENCE
(1). Verify incorporation of all Technical Publication Index (TPI) avail-

outstanding Service Bulle- able through Zodiac Services website:
tins and Service Information http://tpi.services.zodiacaerospace.com/
Letters. technical/tpi
Refer to Introduction section (Para. 2) of
this CMM.
(2). Reservoir and Valve Assem- Inflation CMM 25-65-20.
bly
(a). Perform Inflation Valve See Testing section in Inflation CMM
Pull Force Test 25-65-20.
(b). Leakage Test
(c). Reservoir Requalification*
(d). Perform all steps in Check See Check section in Inflation CMM
section. 25-65-20.
(e). Replace Valve/Regulator
Reservoir Fitting. (Ref. See Disassembly and Assembly sec-
S.I.L. 25-181 for P/N). tions in Inflation CMM 25-65-20.
NOTE: Individual valve compo-
nents are only to be
checked if valve has been
disassembled.
*Reference applicable DOT specification or special permit on reservoir for

requalification interval and service life.
** The first maintenance shall be performed three years from the evacuation
system’s date of manufacture.
NOTE: Instructions detailed herein serve as a general guideline for

reservoir requalification (i.e. Visual Inspection, Hydrostatic
Testing, etc.). All inspection and testing shall be performed in
accordance with the applicable governing DOT Regulations by
DOT-Approved Facilities.
INTRO-9, 13 Nov 2015

25-66-07 INTRO-10, Blank
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TABLE OF CONTENTS
DESCRIPTION AND OPERATION
Page
1. Leading Particulars 2
2. Evacuation Slide Assembly Description 3
3. Installation and Operation 8
Page 1
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1. Leading Particulars
DESCRIPTION/VALUE
ITEM
EVACUATION SLIDE PART NUMBER
61621-469
Type of Slide Single Lane
Type of Deployment Automatic
Slide Material Silver, Reflective Urethane -Coated
(Body) Nylon
(Floor) Grey, Reflective Elastomer -Coated
Nylon
Valise Material Yellow, Urethane-Coated Nylon
Length of Slide 186 ± 3 In. (Nominal)
Inflated volume 60.0 Cu. Ft. (Nominal)
Operating pressure 2.1 psig to 3.2 psig
Range at 70°F (21.1°C) (1.5 N/cm2 to 2.2 N/cm2)
System Maximum Weight 36 Lb. (16.2 kg) Max.
Lighting System Alkaline Battery and Incandescent
Lamps
LEADING PARTICULARS
TABLE 1
Page 2
25-66-07 13 Nov 2015
61621
2. Evacuation Slide Assembly Description
A. The evacuation slide is designed to provide a safe, reliable and efficient

means of rapid egress from the aircraft. The major subsystems include
the inflatable and a stored gas reservoir/valve assembly, both of which
are packed in a urethane-coated fabric valise.
B. The inflatable is a rectangular structure consisting of two longitudinal
tubes which are connected at each end by a sill tube and a runway
tube. The sliding surface or “floor” of the slide is attached as a taut
membrane between the tubes, along the length of the slide. This struc-
ture can withstand simultaneously the weight of up to four evacuees.
The lower end of the slide body is curved to form a “hook” which
changes the angle of the sliding surface at the runway end and serves
to slow the rate of descent.
C. The slide is constructed from lightweight heat-reflective, urethane
coated nylon fabric. Excellent puncture, tear, and abrasion resistance
of the sliding surface and tube structures, lessens the chance of pene-
tration from a sharp object (i.e. footwear).
D. No fail handles are located at both sides on the runway end of the
inflatable for use of the slide as a non-inflatable apron chute. Persons
on the ground may grasp these handles to extend the slide into a hand-
held chute if pressure loss within the inflatable is evident.
E. A re-entry strap/webbing is provided in the event that reboarding the
aircraft is required after an evacuation.
F. A frangible link is used to control the deployment sequence in a pre-
dictable, repeatable manner. The link is a precision tension fuse which
separates at a pre-determined force value. The link is connected to
webbing grommet tabs which are permanently attached to the inflat-
able.
G. A relief valve installed on the underside of the inflatable limits the max-
imum pressure. Relief valve operating pressure is approximately 2.25
psig (1.6 N/cm2) for P/N B18245-5 and 3.2 psig (2.2 N/cm2) for P/N
64154-5.
H. In order to facilitate use of the slide as a flotation device, it is equipped
with permanently attached webbing grasp lines (flotation handles) for
survivors in the water, constructed of 1 In. (25.4 mm) wide webbing.
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I. The mooring line is approximately 20 Ft. (6.1 m) long with automatic

(92, IPL Figure 1) and manual (91, IPL Figure 1) separation devices.
The automatic release (92, IPL Figure 1) is a fabric membrane which
separates when approximately 525 Lb. (238 kg) of tension is applied to
the mooring line and the manual release (91, IPL Figure 1) incorpo-
rates a parachute pin and cone closure which separates upon removal
of the parachute pin.
J. The lighting system is located across the runway tube and along side
the sliding lane to illuminate the area in front and along the length of
the slide. It is automatically actuated and powered by an alkaline bat-
tery.
K. The reservoir and valve inflation assembly is installed in a fabric sling
attached to the inflatable. The reservoir is a composite structure con-
sisting of a seamless aluminum liner reinforced with overlapping Kevlar
or Carbon filaments bonded with epoxy resin. The reservoir capacity is
200 Cu. In. (3.28 liters). The stored gas reservoir contains a 30% CO2
and 70% nitrogen mixture by weight at a pressure of 3000 psig at +
70° F (2068 N/cm2 at + 21.1°C). A valve/regulator assembly is installed
on the reservoir to regulate the discharge pressure from approximately
270 psig (186 N/cm2) when the reservoir is at 3000 psig (2068 N/cm2)
to a pressure of approximately 460 psig (317 N/cm2) as the reservoir
pressure decays.
L. The valve/regulator has a “ball” type valve section which retains the
gas charge and a spring loaded poppet for controlling the outlet pres-
sure when the valve is opened. A frangible “rupture” disc relief device
limits the pressure buildup in the storage reservoir to 4500 psig (3100
N/cm2). A filler valve is used to charge the valve reservoir and a fusible
plug for overtemperature protection.
M. A direct reading temperature compensated pressure gage indicates
the reservoir gas charge level.
N. A pull handle for manual actuation serves as a backup should the slide
fail to inflate automatically after opening of the door. The pull handle,
triangular in shape, is constructed of white webbing and a red colored
metallic handle which reads “PULL” in white letters.
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O. An aspirator assembly is located in the end of the sill tube of the inflat-
able. It is comprised of an ambient inlet housing section, which con-
tains a nozzle array, and a cylindrical diffuser and mixing tube. The inlet
housing is equipped with one-way flappers which act as check valves.
The aspirator functions as an ejector to entrain ambient air by the
induction effect from the expansion of high-pressure stored gas
through the nozzle array. Inflation time is rapid and the reservoir size is
minimized.
P. The aspirator is mounted to the inflatable by clamping it into a molded
urethane flange. A clamp retains the aspirator into the molded flange.
The clamp is covered with tape to prevent chafing the inflatable. The
aspirator is also equipped with a pressure test valve for checking the
slide pressure and for inflating the slide in the shop.
Q. A flexible double-braided reinforced high pressure hose assembly con-
nects the reservoir and valve to the aspirator. The hose is equipped
with swivel fittings at each end.
R. The valise is constructed of yellow urethane-coated nylon fabric and
has a pressure gage viewing window to permit monitoring of the gas
pressure of the reservoir and valve/regulator assembly.
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MANUAL INFLATION PULL HANDLE
DETACHABLE GIRT
RELEASE HANDLE
GIRT ATTACHMENT
ASPIRATOR
FRANGIBLE LINK/RESTRAINT
MOORING
LINE
RAIL POSITIONERS
(SECONDARY RESTRAINTS)
LAMP HARNESS
RE-ENTRY WEBBING
SLIDING SURFACE (FLOOR)
TOP VIEW
EVACUATION SLIDE ASSEMBLY (SHOWN INFLATED)

FIGURE 1
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HOSE ASSEMBLY
VALVE/REGULATOR
ASSEMBLY
RESERVOIR
PRESSURE GAGE
POWER UNIT
RELIEF VALVE
RESTRAINT
RESERVOIR SLING
WEBBING GRASP LINE

(FLOTATION HANDLE)
NO-FAIL HANDLE
BOTTOM VIEW
EVACUATION SLIDE ASSEMBLY (SHOWN INFLATED)

FIGURE 2
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3. Installation and Operation
A. The slide system is installed in a storage pan on the aircraft door per
the instructions in the Aircraft Maintenance Manual. In the armed
mode, the inflatable is connected to the aircraft door sill by the girt bar
which is installed through a sleeve in the girt and retained to the aircraft
by floor brackets. The girt is attached to the slide sill tube assembly by
a series of interlocking white nylon cord loops (daisy chain). The loops
are retained by a pin installed through the cord loop and breakaway
tied with white nylon thread. A pull handle/cable attached to the pin
permits the pin to be withdrawn which causes the girt to separate. This
girt separation cable and cord loop arrangement is located under a pro-
tective flap and provides an expedient means of detaching the inflated
slide from the aircraft. (e.g., to facilitate removal after deployment or to
permit its use as an auxiliary flotation device).
B. As the aircraft door opens, the storage pan opens, and the packed
slide drops outboard over the aircraft door sill. The inflation cable ten-
sions and opens the valve/regulator assembly. The stored gas dis-
charges through the hose assembly into the aspirator. Initiation of
inflation separates the valise Velcro closures, and the slide pressurizes
to achieve design shape.
C. Actuation of the inflation valve causes primary gas to be released from
the reservoir into the hose attached to an aspirator. The primary gas
expands through and aspirator nozzles and causes the mixing tube to
ingest ambient air through the open “flappers”. The flappers act as a
check valve and close when the inflatable pressure reaches approxi-
mately 1.5 psig (1.0 N/cm2). The remaining gas from the reservoir then
flows directly into the inflatable increasing the pressure to the operating
range.
D. If the slide does not inflate automatically, it can be inflated manually by
using the pull handle assembly. This handle tensions the inflation cable
mounted on the right side of the girt to open the valve/regulator assem-
bly and initiate deployment.
E. Separation of the inflatable from the aircraft to permit its use as a flota-
tion device is accomplished as follows:
(1). Pull the release handle, located beneath a cover flap on the girt
extension.
(2). The girt will separate and the slide will drift from the aircraft.
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RESERVOIR/VALVE ASSEMBLY
PRESSURE GAGE
VIEWING PORT
LOCK PIN STOWAGE
POCKET
VALISE
GIRT BAR
LOCK PIN
DETACHABLE GIRT ASSEMBLY
PULL HANDLE PACKED INFLATABLE

INFLATION CABLE
EVACUATION SLIDE ASSEMBLY

(SHOWN IN PACKED CONFIGURATION)
FIGURE 3
Page 9, 13 Nov 2015

25-66-07 Page 10, Blank
61621
TABLE OF CONTENTS
TESTING AND FAULT ISOLATION
Page
1. Testing Materials/Equipment 102
2. Test Setup 104
3. Testing of Inflatable System 104
4. Fault Isolation 132
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1. Testing Materials/Equipment (Table 101)
NOTE: Drawings of equipment/tools manufactured by Air Cruisers are

available from Air Cruisers upon request.
NOTE: Equivalent substitutes may be used for items when marked
with the following symbol 
ITEM/DESCRIPTION QUANTITY SOURCE USE

Leak Test Solution As Commercially Determines leakage of
Clear Ivory Hand Washing Required Available inflatable assemblies.
Dish Liquid Detergent 
One ounce (29.6 milliliters) of detergent mixed to every 64 ounces (1.9 liters) of
water
Test Set (Light System) 1 D.M.E. Corp. Verifies power unit volt-
Model TU-12 or TU-14 V55827 age and lamp harness
amperage.
Test Set (Light System) 1 BaseWest, Inc. Verifies power unit volt-
Model TS-420 V0MF00 age and lamp harness
(Alternative to TU-14) amperage.
Manometer (water) 1 Commercially Measures pressure of
0 to 5.0 psig Available inflatable assembly.
(0 to 3.4 N/cm2) * 
Manometer (Meriam Fluid) 1 Commercially Measures pressure of
0.5 to 5.0 psig Available inflatable assembly.
(0.3 to 3.4 N/cm2)
[9.4 In. (238.8 mm) M. F.
per 1.0 psig (0.7 N/cm2)] * 
Barometer 1 Commercially Measures ambient
[Scale increments not more Available pressure.
than 0.1 In. (2.5 mm)] 
*Alternatives
TESTING MATERIALS/EQUIPMENT
TABLE 101 (SHEET 1 OF 3)
Page 102
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Stopwatch, Plain Timer 1 Commercially Measures inflation time of
(1/10 Seconds Gradua- Available system during functional
tions)  deployment test.
Pressure Gage 1 Commercially Measures pressure of
(Mechanical/Digital) Available inflatable assembly.
Scale Range 0 to 15 psig
(0 to 10.3 N/cm2) * 
2.0% Accuracy
Thermometer 1 Commercially Measures ambient tem-
[Scale increments not more Available perature.
than 1°F (0.6 °C)] 
Tool - Adapter, Pressure 1 Air Cruisers Connects manometer/
Test Valve V70167 pressure gage to pres-
C37099-103 sure test valve for inflat-
able assembly pressure
reading.
Tool - Valve Core 1 Rus Industries Installs/removes valve
6914V-SD Inc. core from pressure test
V8S111 valve assemblies.
Relief Valve Test Clamp 1 Air Cruisers Retains relief valve in
TO5862 V70167 “closed” position; prohib-
(Post S.B. 737 103-25-31) its inflatable assembly
pressure loss during
overpressure or leakage
testing.
Test-Plug 1 Air Cruisers Replaces relief valve;
C19851-101 V70167 prohibits inflatable
(Pre S.B. 737 103-25-31) assembly pressure loss
during overpressure test-
ing.
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Tool - Relief Valve TO2298 1 Air Cruisers Installs/removes relief
(Pre S.B. 737 103-25-31) V70167 valve.
Hydrostatic Test Machine 1 Air Cruisers Overpressure tests
TO4853  V70167 hose assemblies.
Pipe Thread Sealing As Federal Aspirator pressure test
Compound No. 2 Required Process Corp. valve installation leak-
PLS2* V3CKH7 age deterrent.
Nickel Coated Teflon Tape As Air Cruisers Aspirator pressure test
M12243* Required V70167 valve installation leak-
age deterrent.
Teflon Tape As Commercially Aspirator pressure test
AA-58092-2-1* Required Available valve installation leak-
age deterrent.
Tool - Installation/Removal, 1 Mirada Installs/removes
and Handle Research & inflate/deflate and
B51025 and A51280 Mfg. Co. relief valves.
(Post S.B. 737 103-25-31) V08407
Protective Blanket 1 Commercially Personnel safety
Furniture Moving Type Available equipment used during
(Quilted polyester fabric overpressure testing.
with cotton stuffing)
Minimum Approximate size
80 x 72 In.(2032 x 1829
mm) and weight
6.25 Lb. (2.8 kg) 
Fixture, Overpressure 1 Air Cruisers Personnel safety
TO6762-1 V70167 equipment used during
overpressure testing.
*Alternatives for aspirator pressure test valve installation only.
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2. Test Setup
A. Testing of components is accomplished on the inflatable with all com-

ponents assembled as an operational system.
WARNING: USE EYE, FACE, AND EAR PROTECTION WHEN
USING HIGH PRESSURE AIR TO PROTECT PERSON-
NEL FROM POSSIBLE INJURY.
NOTE: The shop compressed air source should be free of oil and
moisture and incorporate a 20 micron filter.
B. Attachment of inflation shop air source or manometer testing equip-
ment to the aspirator pressure test valve is accomplished using the
adapter (Table 101).
3. Testing of Inflatable System
NOTE: There are two acceptable Functional Tests, 3.A, Trial Inflation
(Functional Deployment Test), an actual trial inflation per-
formed off the aircraft or, 3.B, Floor Run Functional Test, a trial
inflation performed on a shop floor.
A. Trial Inflation (Functional Deployment Test)
(1). A system function test may be performed by deploying the slide
from the aircraft at time of removal for maintenance check.
NOTE: If an aircraft is unavailable, see Paragraph 3.B. Floor Run Test.
(2). The deployment area should be covered with carpeting or other
protective material.
(3). Check the reservoir and valve inflation assembly pressure gage
for the proper gas charge reading prior to deployment. See Check
section.
(4). Inflation time, 2.5 seconds, can be obtained by measuring, with a
stopwatch, the time from initiation of inflation until the inflatable is
fully extended.
(5). Normal operating pressure for the evacuation slide is
2.1 psig (1.5 N/cm2) to 3.2 psig (2.2 N/cm2). Check
immediately, to within 5 minutes, after deployment with a manom-
eter or pressure gage (Table 101) connected to the pressure test
valve.
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(6). Upon completion of test, immediately reinstall the lanyard assem-

bly into the power unit to prevent unnecessary usage of power
source.
(7). If performance requirements are not met, the equipment is not
functioning properly. Isolate the cause (see Paragraph 4, Fault
Isolation) and correct the problem(s) before returning the slide
assembly to service.
(8). Remove the slide from the aircraft. See Aircraft Maintenance
Manual.
B. Floor Run Functional Test
NOTE: Use this procedure to functionally test a system on the shop
floor instead of deploying from an aircraft.
NOTE: The inflation test area must be carpeted to protect the slide
components from damage by abrasion due to contact with the
floor.
NOTE: A minimum of three persons is recommended to support the
test.
• Test director to initiate inflation and to time the process
• One person to hold the aspirator
• One person to read the pressure measuring instrument
CAUTION: ENSURE FRANGIBLE LINKS ARE DISCONNECTED
(SEE DISASSEMBLY SECTION).
(1). Remove the slide from the valise and unfold per the
Disassembly section.
(2). Extend slide to its full length and width with floor side up.
(3). Check pressure gage on reservoir to insure gage pointer is within
limits of green band.
WARNING: HOLD ASPIRATOR AT ARMS LENGTH AND OFF THE
FLOOR WITH OPENING AWAY FROM THE FACE AND
AWAY FROM LOOSE OBJECTS WITHIN 6 FEET (1.8 m)
TO PREVENT DAMAGE OR INJURY FROM HIGH PRES-
SURE AIR.
(4). Remove the lock pin (if applicable) from the valve.
NOTE: Record time in seconds to when slide is fully formed.
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(5). Initiate inflation by pulling the inflation cable from the valve and
record time to when slide is fully formed. Time should be 4.0 sec-
onds maximum.
(6). Within 1 to 5 minutes following gas discharge, connect adapter
(Table 101) and manometer (Table 101) to the pressure test valve
and record pressure.
(7). Normal operating pressure for the evacuation slide is 1.5 psig
(1.0 N/cm2) minimum.
(8). If performance requirements are not met, the equipment is not
functioning properly. Isolate the cause (see Paragraph 4, Fault
Isolation) and correct the problem(s) before returning the slide
assembly to service.
RELIEF VALVE
RELIEF VALVE
PLUG
RELIEF VALVE, P/N B18254-5, PLUG INSTALLATION

(PRE S.B. 737 103-25-31)
FIGURE 101
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RELIEF VALVE
TEST CLAMP
(TO5862)
RELIEF VALVE
RELIEF VALVE, P/N 64154-5, TEST CLAMP INSTALLATION

(POST SB 737 103-25-31)
FIGURE 102
C. Inflatable Integrity Verification Tests
CAUTION: PERFORM A LEAKAGE TEST AND AN OVERPRES-

SURE TEST AFTER ANY REPAIR WHICH COULD
AFFECT AIR RETENTION CAPABILITIES. THIS WOULD
NOT INCLUDE REPLACEMENT OF ASPIRATOR OR
RELIEF VALVE.
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OVERPRESSURE
FIXTURE
SLIDE
(TYP.)
OVERPRESSURE FIXTURE PLACEMENT (TYPICAL)

FIGURE 103
(1). Overpressure Test

(a). Remove the relief valve using the appropriate relief valve tool
(Table 101).
(b). Pre S.B. 737 103-25-31, install relief valve plug (Table 101,
Figure 101) using the relief valve tool TO2298 (Table 101) and
torque wrench. Tighten per Table 801. Post S.B. 373 103-25-
31, use relief valve test clamp (Table 101, Figure 102), to
secure the relief valve.
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(c). Hold the aspirator flapper valves open; position shop air nozzle
approximately three to four inches away from the aspirator inlet
(flapper valve); add air until the slide inflates (rounds out) to
design shape. Allow aspirator flapper valves to close.
WARNING: PLACE OVERPRESSURE FIXTURE (TABLE 101) OVER
AND IN FRONT OF ASPIRATOR TO PROTECT PER-
SONNEL FROM POSSIBLE INJURY.
WARNING: PLACE PROTECTIVE BLANKETS (TABLE 101) OVER
MIDDLE OF LEFT AND RIGHT SIDES OF TOP TUBE TO
PROTECT PERSONNEL FROM POSSIBLE INJURY.
(d). Place protective blankets (Table 101) over inflatable.
(e). Position overpressure fixture (Table 101; Figure 103) in front of
aspirator.
WARNING: CHECK INFLATABLE PRESSURE TO ASSURE THAT
THE MAXIMUM SPECIFIED VALUE IS NOT EXCEEDED
AND COMPROMISING INFLATABLE INTEGRITY.
(f). Remove cap from pressure test valve on aspirator. Install
adapter (Table 101) to the pressure test valve and attach air
line to adapter.
(g). Increase pressure to 3.5 psig (2.4 N/cm2).
(h). Remove air line.
NOTE: Measure the pressure with a manometer or gage calibrated in
increments not greater than 0.1 psig (0.07 N/cm2) (Figure 101)
connected to the pressure test valve.
(i). Record pressure and time of day.
(j). Allow the slide to stand undisturbed for five minutes.
CAUTION: PRE S.B. 737 103-25-31, REMOVE RELIEF VALVE TEST

PLUG AND RE-INSTALL RELIEF VALVE.
CAUTION: POST S.B. 737 103-25-31, REMOVE RELIEF VALVE
TEST CLAMP.
(k). Check slide for structure degradation, lifts, seam separation, or
material fatigue. None is permissible. There shall be no evi-
dence of construction or material failure. All seams and acces-
sories shall remain intact and show no evidence of separation.
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(l). Remove protective blankets and overpressure fixture from

slide.
(m).Deflate the slide assembly, remove pressure test valve
adapter, and install cap. Pre S.B. 737 103-25-31, remove the
relief valve test plug, (Table 101) and install relief valve. Post
S.B. 737 103-25-31, remove relief valve test clamp (Table 101).
See Assembly section.
(2). Leakage Test
CAUTION: PERFORM A LEAKAGE TEST AND AN OVERPSURE
TEST AFTER ANY REPAIR WHICH COULD AFFECT AIR
RETENTION CAPABILITIES. THIS WOULD NOT
INCLUDE REPLACEMENT OF ASPIRATORS OR RELIEF
VALVE.
NOTE: If overpressure test was previously conducted and system is
inflated, proceed to Paragraph 3.C.(2).(b), for “inflated state”
instructions.
(a). Hold the aspirator flapper valves open; position the air nozzle
approximately three to four inches (76.2 to 101.6 mm) away
from the aspirator inlet (flapper valves). Add air until the slide
inflates (rounds out) to design shape. Allow the aspirator flap-
per valves to close.
NOTE: Measure pressure with a manometer or gage calibrated in
increments not greater than 0.1 psig (0.07 N/cm2) (Table 101)
connected to the pressure test valve.
(b). From a deflated state, inflate the unit 0.25 psig (0.17 N/cm2)
over the required on-test pressure.
From an inflated state (i.e. overpressure test), deflate the unit
0.25-0.50 psig (0.17-0.35 N/cm2) below the required on-test
pressure.
(c). Remove cap from pressure test valve on aspirator. Install pres-
sure test adapter tool (Table 101), to pressure test valve on
aspirator. Attach air line to adapter, and add air. Top-off tube
pressure to 2.0 psig (1.4 N/cm2).
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SLIDE ASSEMBLY
ASPIRATOR
FLAPPER
VALVES
PRESSURE TEST
VALVE
SHOP AIR HOSE
CAP
AIR LINE
SLIDE LEAKAGE TEST

FIGURE 104
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(d). Remove air line and adapter. Install cap on pressure test valve.
(e). Allow the slide to stabilize for one hour.
(f). After one hour, check and readjust the pressure to 2.0 psig
(1.4 N/cm2) if necessary.
(g). Record slide pressure, temperature, barometric pressure, and
time of day.
(h). Allow the slide assembly to stand undisturbed for the desired
test interval (four hours minimum is recommended). Record
the slide pressure, temperature, barometric pressure, and time
of day at the end of the pressure test. Remove pressure test
valve adapter, and install cap.
NOTE: The minimum permissible slide pressure is shown in Figure
105 after correction for temperature and barometric pressure
variations. Correct for temperature variations by subtracting
0.1 psig (0.07 N/cm2) for every 3°F (1.7°C) rise in temperature
or by adding 0.1 psig (0.07 N/cm2) for every 3°F (1.7°C) fall.
Correct for barometric changes. If the barometric pressure
decreased subtract 0.1 psig (0.07 N/cm2) to the final gage
reading for every 0.2 In. (5.08 mm) of mercury decrease. If the
barometric pressure increased add 0.1 psig (0.07 N/cm2) to
the final gage reading for every 0.2 In. (5.08 mm) of mercury
increase.
CAUTION: TO PREVENT MOLD OR MILDEW GROWTH, OR THE
POSSIBLE DISCOLORATION OR COLOR TRANSFER
FROM VARIOUS COMPONENTS, UNITS SHOULD BE
ALLOWED TO DRY THOROUGHLY PRIOR TO ROLL-
ING UP FOR TEMPORARY STORAGE OR FINAL PACK-
ING.
(i). If the corrected pressure has fallen below specified limits in
Figure 105, reinflate the slide to 2.5 psig (1.7 N/cm2). Check for
relief valve leakage per Paragraphs 3.D or 3.E. Check for aspi-
rator and pressure test valve leakage per Paragraph 3.F.
Check for inflatable leaks by swabbing the tubes with leak test
solution (Table 101) using a soft brush, or cloth.
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2.5
PRESSURE OF INFLATABLE (PSIG)
2.0
1.5
1.0
2 4 6 8 10 12
TIME ON TEST (HOURS) AFTER STABILIZATION
MINIMUM ALLOWABLE SLIDE PRESSURE VS. TEST DURATION

FIGURE 105
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D. Relief Valve Leakage Test (P/N B18254-5) (Figure 106)

(Pre S.B. 737 103-25-31)
(1). Apply leak test solution (Table 101) by brushing around the relief
valve (220, IPL Figure 1) sealing area.
(2). If bubbling occurs (indicating a leak) at the sealing area, tighten
relief valve per Table 801.
(3). The relief valve should open at 2.25 ± 0.25 psig (1.6 ± 0.2 N/cm2)
and close at 1.9 psig (1.3 N/cm2) minimum.
NOTE: If the relief valve does not operate within the limits, replace.
APPLY LEAK TEST SLIDE FABRIC

SOLUTION IN THIS AREA
FLANGE
RELIEF VALVE
RELIEF VALVE LEAKAGE TEST

FIGURE 106
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E. Relief Valve Leakage Test (P/N 64154-5) (Figure 107)

(S/N 1570A, and 1568A, 1567A, 1561A, and 1572A and Subs)
(Post S.B. 737 103-25-31)
(1). Apply leak test solution (Table 101) by brushing around the relief
valve sealing area and the opening and closing portion of the
relief valve.
(2). If bubbling occurs (indicating a leak) at the sealing area, tighten
relief valve per Table 801.
(3). If bubbling continues, remove relief valve and replace gasket and/
or replace relief valve.
(4). If bubbling occurs at opening and closing area, replace relief
valve.
(5). The relief valve opens at 3.2 psig (2.2 N/cm2) maximum and
closes at 2.4 psig (1.7 N/cm2) minimum.
NOTE: If the relief valve does not operate within limits, replace.
OPENING AND CLOSING

AREA
RELIEF VALVE
SEALING AREA FLANGE
RELIEF VALVE LEAKAGE TEST

FIGURE 107
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F. Aspirator and Pressure Test Valve Leakage Test (Figure 108)

NOTE: Perform this test after aspirator replacement.
(1). Using a brush, apply leak test solution (Table 101) at the sealing
flange.
(2). Check the joint between the inlet housing and the sealing flange.
(3). If bubbling occurs at the sealing flange (indicating a leak), tighten
worm drive clamp screw (Table 801).
NOTE: If leakage is detected, replace aspirator.
(4). Apply the leak test solution (Table 101) with a brush to the flapper
valve seat area of the ambient air inlet. If bubbling occurs (indicat-
ing a leak), replace the aspirator.
CAUTION: WHEN DRYING PARTS WITH COMPRESSED AIR JET,
AVOID DIRECTING THE AIR ONTO THE FLAPPER
VALVES SINCE THE VALVES MAY UNSEAT, CAUSING
SLIDE PRESSURE TO DROP.
(5). Dry parts using compressed air.
BRUSH
SEALING
LEAK TEST SOLUTION FLANGE
ASPIRATOR WORM DRIVE

CLAMP SCREW
FLAPPER
VALVE SEAT
BRUSH
LEAK TEST
SOLUTION
ASPIRATOR AND PRESSURE TEST VALVE LEAKAGE TEST

FIGURE 108
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F. Aspirator and Pressure Test Valve Leakage Test (Cont’d)

(Figure 109)
(6). Remove pressure test valve cap.
(7). Apply leak test solution (Table 101) with a brush to the valve body
and the valve base. If bubbling occurs at the base (indicating a
leak) remove valve body, apply sealing compound (Table 101) or
Teflon tape (Table 101) to threads and re-install. If Teflon tape is
used, apply as follows:
(a). Thoroughly clean and degrease male and female threads
assuring the removal of all previously applied anti-seize com-
pound or tape.
CAUTION: IN NO CASE WILL THE TAPE BE PERMITTED TO
EXTEND BEYOND THE FIRST THREAD.
NOTE: Apply tension on tape while wrapping.
(b). Wrap tape tightly in direction of the thread spiral of the male
pipe thread beginning with the first thread.
(c). Using care not to contaminate tape, encircle the threads and
join together with a very slight overlap, not more than half of
the tape width.
(d). Press tightly on tape. Cut tape using scissors. Ensure tape is
tight and remains at the first thread of fitting. Lose ends are not
permitted. Pipe thread is now ready for joining.
(e). If removal of Teflon tape is necessary, hold valve at such an
angle as to ensure that any loose Teflon tape fragments cannot
fall into valve or adjacent components.
(8). Re-install and/or replace valve. Tighten per Table 801.
CAUTION: WHEN DRYING PARTS WITH COMPRESSED AIR JET,
AVOID DIRECTING AIR ONTO FLAPPER VALVES
SINCE, THE VALVES MAY UNSEAT, CAUSING SLIDE
PRESSURE TO DROP.
(9). Dry parts using compressed air.
(10). Replace cap and hand tighten.
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VALVE BASE
VALVE BODY
ASPIRATOR
PRESSURE TEST
VALVE CAP
BRUSH
LEAK TEST
SOLUTION
ASPIRATOR AND PRESSURE TEST VALVE LEAKAGE TEST

FIGURE 109
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G. Hose Integrity Verification

(1). Perform a hose integrity verification test at every 3 years coinci-
dent with system level maintenance.
NOTE: The recommended hydrostatic test and inspection schedule is
every three years, up to and including 15 years. After 15 years
of age, test annually.
(2). Perform a hydrostatic test, using hydrostatic test machine
TO4853 (Table 101), at 900 psig (620.5 N/cm2) for a time period
of three to five minutes. Replace the hose if evidence of perma-
nent distortion or leakage is observed.
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H. Light System Test (TU-12 Test Unit) (Figure 110)

NOTE: The light system can be checked during the slide leakage test.
NOTE: The TU-12 test unit is no longer available from DME Corpora-
tion. TU-14 is available as a higher reliability replacement test
unit. See Paragraph 3.I for TU-14 Light System Test.
(1). Check the power unit expiration date. Replace if expiration date is
sooner that next scheduled maintenance date.
(2). Check that all electrical connections between the lamp harness,
power unit, test set, and test adapter are properly connected, and
that pin on light activating lanyard is installed in power unit.
(3). Set load selector knob to C (Figure 110).
(4). Install the four pin test connectors from the power unit in test
receptacle.
(5). Move TU-12 arm switch to “Arm” position.
(6). Depress TU-12 activate switch to activate test unit.
(7). Depress Battery-Test-Button for 3-4 seconds and release. Record
end voltage appearing on voltmeter. Voltage must be 10.2 volts or
greater.
(8). Depress the Lamp-Test -Button until the ampere reading on
ammeter is stabilized. Release the test button; the ampere read-
ing must be within .717 - .908 amperes.
(9). If this is a Post-pack test, verify that the reading is within .030
amperes of the Pre-pack readings.
NOTE: An ammeter reading below the acceptable amperage range or
a Post-pack ammeter reading differing from the Pre-pack read-
ing by greater than .030 amperes indicates a possible broken
or burned out lamp in the THS lamp harness.
An ammeter reading that is higher than the acceptable amper-
age range indicates the possibility of a short circuit.
To replace a lamp or entire lamp harness see Repair section.
CAUTION: ENSURE PIN IS RE-INSTALLED IMMEDIATELY OR
POWER UNIT WILL BE UNNECESSARILY DIS-
CHARGED.
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LAMP HARNESS
FOUR
PIN
SWITCH TEST
PIN/LANYARD POWER UNIT CONNECTOR
LAMP HARNESS
TEST BUTTON
POWER UNIT TEST
TEST BUTTON JACKS
VOLTMETER
TEST CONNECTORS
VOLTMETER
PUSH TO TEST POWER UNIT
POWER UNIT TEST
ONLY
TEST
RECEPTACLE
LAMP AND
HARNESS LAMP TEST
AMMETER PUSH TO TEST TS-10

TS-10 PROCEDURE
AMMETER D PROCEDURE ONLY
C
E
OFF ARM
MODEL TU-12
B F TEST UNIT
A
LOAD SELECTOR ACTIVATE
TU-12 TEST UNIT

FIGURE 110
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I. Light System Test (TU-14 Test Set) (Figures 111 and 112)
NOTE: Prior to packing, perform a visual check to verify that each
lamp is operating; “pre-pack” amperage (current) readings are
compared to readings taken “post-pack” to ensure that all
lamps are operating.
(1). Check the power unit expiration date. Replace if the expiration
date is sooner than the next scheduled maintenance date.
(2). Check the condition of the TU-14 internal rechargeable battery as
follows:
(a). Press the ON/OFF power switch S1and release when the ON
indicator LED illuminates. See the chart below for battery sta-
tus LED indicator light indications.
TU-14 BATTERY STATUS LIGHTS INDICATION
No battery status, all OK for test;

LED’s are illuminated Battery charge is OK
YELLOW ON (Flashing) Rechargeable battery pack has reached
its near-end-of-useful-charge at 11.2
loaded volts. Use of the TU-14 may con-
tinue for a short time.
RED ON Rechargeable battery pack has reached
its end-of useful-charge at 10.0 volts. Use
of the TU-14 should be discontinued until
the battery pack is recharged. TU-14
readings obtained while this LED is illumi-
nated are unreliable.
GREEN ON Internal battery charging is in progress.
NOTE: The TU-14 internal rechargeable battery pack is charged at a

120mA rate when the TU-14 is connected, via the TU-14 115
VAC line cord, to a 115 VAC source. Charging is indicated by
the illumination of the CHARGING (green) LED.
The TU-14 rechargeable battery pack should return to full
charge within approximately sixteen hours of charging.
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NOTE: To prevent damage to the connectors/cables when connecting

and disconnecting the test or extension cables, grasp the con-
nector body instead of pulling on the cable wire.
(3). Connect the four-pin test connector from the power unit to the test
receptacle J3 on the front panel. An extension cable, available
from DME Corporation, may be utilized.
(4). Rotate the Load selector switch S6 to the load C.
(5). Press and hold the BAS load test switch S5.
(6). After a three second stabilization period, verify the voltmeter
reading is at or above the minimum specified reading of 10.2
volts.
(7). Release the BAS load test switch S5.
(8). Press and hold the Lamp Harness test switch S4.
(a). For a pre-pack test, allow three seconds for stabilization and
record the TU-14 ammeter reading. Verify that all lamps are
illuminated. The acceptable amperage range is .761 to .983
amperes for 62929-SER series and .841 to 1.063 amperes for
D19860-SER series.
(b). For a post-pack reading, verify that the ammeter reading is
within +/- .030 amperes of the pre-pack reading.
NOTE: A post-pack reading which falls beyond the above range indi-
cates the possibility of a system short, and/or a broken or
defective lamp.
NOTE: To replace an individual lamp or an entire lamp harness, refer
to the Repair section of the respective ZAES Component
Maintenance Manual.
(9). Release lamp harness test switch S4. Test is complete.
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YELLOW TU-14 BATTERY
NEEDS
CHARGE
GREEN
CHARGING
RED
LOW
WARNING-SHOCK HAZARD
UNPLUG POWER CORD BEFORE
SERVICING INSIDE UNIT
CORPORATION
FORT LAUDERDALE
J4 FLORIDA
J-1 E-1 E-2 J-3

115 VAC
MODEL TU-14 TU-14 BATTERY
TEST SET NEEDS
FUSE CHARGE
1 AMP
CHARGING
C D
LOW
S-6
B
E VOLTMETER AMMETER
VOLTS AMPS ON
A F S-5 S-2 S-4 S-3 S-1
LOAD BAS LAMP TS-10 POWER

LOAD HARNESS PROCEDURE
BATTERY TEST TEST
TU-14 TEST SET

FIGURE 111
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LAMP HARNESS
LAMP HARNESS CONNECTORS
POWER UNIT
CONNECTORS
SWITCH PIN/LANYARD POWER UNIT FOUR PIN

TEST CONNECTOR
TEST RECEPTACLE
WARNING-SHOCK HAZARD
SERVICING INSIDE UNIT CORPORATION
FORT LAUDERDALE
J4 FLORIDA
J-1 E-1 E-2 J-3

115 VAC
TEST SET NEEDS
FUSE CHARGE
1 AMP
CHARGING
C D
LOW
S-6
B
E VOLTMETER AMMETER
VOLTS AMPS ON
A F S-5 S-2 S-4 S-3 S-1

BATTERY TEST TEST
LOAD SELECTOR BAS LOAD LAMP HARNESS

TEST SWITCH TEST SWITCH
TU-14 TEST SET

FIGURE 112
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J. Light System Test using the TS-420 Test Set (Figures 113 and 114)
NOTE: Prior to packing, perform a visual check to verify that each
lamp is operating; “pre-pack” amperage (current) readings are
compared to readings taken “post-pack” to ensure that all
lamps are operating.
(1). Check the power unit expiration date. Replace if the expiration
date is sooner than the next scheduled maintenance date.
(2). Check the condition of the TS-420 internal rechargeable battery
as follows:
(a). Place the mode selector switch into the AMMETER position.
(b). Push the PRESS TO TEST button. Observe the SELF TEST
and LOW BATT indicators for the following indications:
SELF TEST BATTERY STATUS

INDICATION
INDICATOR INDICATOR
GREEN OFF OK for test; battery charge is OK.

GREEN YELLOW OK for test; battery is getting low.
Recharge soon.
RED YELLOW Do not use for test; battery is low.
Recharge immediately.
RED or OFF OFF Do not use for test; unit is inoperative.
Return for service.
NOTE: The TS-420 internal rechargeable battery pack is charged at a

200mA nominal rate when the TS-420 is connected, via its
accessory 115VAC source (a 220VAC wall adapter is also
available). A charging indicator light is not provided. Full
charge of a completely depleted battery requires approxi-
mately eight hours. The TS-420 test set has overcharge pro-
tection and may be left on charge for extended periods;
although this is not recommended.
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NOTE: To prevent damage to the connectors/cables when connecting

and disconnecting the test or extension cables, grasp the con-
nector body instead of pulling on the cable wire.
(3). Connect the four-pin test connector from the power unit to the
contact receptacle on the TS-420 test set connector block. An
extension cable, available from BaseWest Incorporated, may be
utilized.
(4). Place the Mode Selector rocker switch into the VOLTMETER
position.
(5). Set the Load Selector rotary switch to load C.
(6). Press and hold the PRESS TO TEST button.
(7). After a three second stabilization period, verify the voltmeter
reading is at or above the minimum specified reading of 10.2
volts.
(8). Release the PRESS TO TEST button.
(9). Shift the Mode Selector rocker switch to the AMMETER position
for pre-and post-pack testing of the lamp harness amperage.
(10). Press the PRESS TO TEST button firmly and release. The unit
will remain ON for about 20 seconds, allowing ample time to ver-
ify that all lamps illuminate.
(11). After a three second stabilization period, record the ammeter
reading. The acceptable amperage range is 761 to 983 milliam-
peres for 62929-SER series and 841 to 1063 milliamperes for
D19860-SER series.
(12). Verify that the post pack ammeter reading is within +/-30 milliam-
peres of the pre-pack reading.
(13). Test is complete
NOTE: A post-pack reading which falls beyond the above range indi-
cates the possibility of a system short, and/or a broken or
defective lamp.
NOTE: To replace an individual lamp or an entire lamp harness, refer
to the Repair section of the respective ZAES Component
Maintenance Manual.
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CONNECTOR BLOCK (VIEW A-A, SEE FIGURE 114)
A A
LCD METER
AC CHARGER
RECEPTACLE
SELF TEST LOW BATT
(5VDC POWER SUPPLY) (INTERNAL BATTERY)
SELF TEST
INDICATOR
BASEWEST
BATTERY
(GREEN/RED LIGHT) STATUS
TS-420 TEST SET
Escape Slide Lighting Systems INDICATOR
(YELLOW LIGHT)
Digital Voltmeter/Ammeter
with 5VDC Power Supply
MODE
SELECTOR
SWITCH LOAD
(VOLTMETER/ VOLTMETER SELECTOR
C D
AMMETER) B SWITCH
A E
NO F
LOAD
AMMETER PRESS TO TEST LOAD SELECTOR
PRESS TO TEST BUTTON
TS-420 TEST SET

FIGURE 113
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VIEW A-A : CONNECTOR BLOCK
AMMETER SYSTEM VOLTMETER

TEST
(+) (-) (+) (-)
FOUR-CONTACT
RECEPTACLE
TS-420 TEST SET

FIGURE 114
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4. Fault Isolation
A. Refer to Table 102 for the fault, most probable cause, and remedy. The
faulty component is determined by isolating the fault to a particular
assembly, and then to the defective part.
FAULT PROBABLE CAUSE REMEDY

Slide Assembly will not Aspirator flapper valve Replace aspirator. See
maintain pressure. not closing properly. Assembly section.
Leaking at aspirator Tighten worm drive clamp
mounting flange. screw, replace if stripped. See
Assembly section.
Hole in fabric. Repair hole. See Repair sec-
tion.
Leaking relief valve. Tighten per Table 801; replace
(64154 valve) gasket. See Assembly and
Disassembly sections.
Leaking pressure test Tighten valve core.
valve on aspirator. See Assembly section.
Tear in fabric. Repair tear. See Repair
section.
Open seam. Repair seam. See Repair
section.
Slide inflates too slowly. Intermediate restraints See Folding Procedure,
not properly installed. P-11990 (APPX-1) for proper
rigging.
Improper gas flow to Check for proper valve regula-
slide. tor setting. See CMM
25-65-20.
Loose hose connections Check O-ring condition and
hose connection torque (Table
801). See Assembly section.
Fabric/foreign object Improper folding. Refer to
ingestion. Folding Procedure P-11990
(APPX-1).
FAULT ISOLATION
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FAULT PROBABLE CAUSE REMEDY

Slide will not inflate. Automatic inflation cable Check cable routing per Fold-
not properly routed or ing Procedure P-11990
connected. (APPX-1).
Inflation assembly not Arm inflation assembly. See
armed. Assembly section in CMM
25-65-20.
Inflation assembly not Determine reason. See Check
charged. and Testing sections. Charge
inflation assembly
per CMM 25-65-20.
Hose assembly not con- Install hose.
nected to aspirator and/or See Assembly section.
inflation valve assembly.
Excessive force required Valve inflation cable See Assembly section in CMM
to pull valve inflation restricted (improper rig- 25-65-20.
cable. ging). Damaged or incor-
rectly assembled inflation
valve assembly.
Inoperative lighting sys- Defective harness Replace applicable
tem. assembly or connections harness per Repair
(all lamps out). section. Retest per Testing sec-
tion.
Poor harness wire con- Replace applicable
nections to power unit. harness per Repair section.
Retest per Testing
section.
Defective power unit. Replace and retest per Testing
section.
Broken or defective lamp. Repair individual lamp.
See Repair section.
Light actuating lanyard Attach per Folding
not rigged properly. Procedure, P-11990
(APPX-1).
FAULT ISOLATION
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TABLE OF CONTENTS
DISASSEMBLY
Page
1. Disassembly Materials/Tools 302
2. General Information 303
3. Remove Slide Assembly From Valise 304
4. Remove Detachable Girt Assembly 312
5. Removal of Mooring Line Assembly 313
6. Removal of Reservoir and Valve Assembly 314
7. Removal of Cable Guide Tube 315
8. Removal of Power Unit 316
9. Unfold Slide 317
10. Removal of Aspirator Assembly 320
11. Removal of Pressure Test Valve 322
12. Removal of Relief Valve (Pre S.B. 737 103-25-31) 323
13. Removal of Relief Valve (Post S.B. 737 103-25-31) 324
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1. Disassembly Materials/Tools (Table 301)

with the following symbol 

Tape, Black Fire Retardant As Air Cruisers Secures valve release
1.0 In. (25.4 mm) wide Required V70167 cable to the cable
M12397-1 guide tube and valve/
(Ref. S.I.L. 25-252) regulator assembly.
Safety Plug 1 Commercially Seals valve outlet port
(Valve Outlet Port) Available to prohibit leakage,
AN814-10 or AS5169-10 damage, and contam-
ination.
Tool - Relief Valve 1 Air Cruisers Installs/removes relief
TO2298 V70167 valve.
(Pre S.B. 737 103-25-31)
Tool - Removal/Installation, 1 Mirada Installs/removes
and Handle Research & inflate/deflate and
B51025 and A51280 Mfg. Co. relief valves.
(Post S.B. 737 103-25-31) V08407
6914V-SD Inc. core from pressure
V8S111 test valve assemblies.
DISASSEMBLY MATERIALS/TOOLS
TABLE 301
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A. Decision to disassemble generally should be based on presence of

leaks, visible damage, or functional discrepancies discovered in perfor-
mance of procedures outlined in Check or Testing and Fault Isolation
sections. Disassemble only to the extent necessary to complete local
repair or replacement. Complete disassembly of all components cov-
ered in this section is neither necessary nor recommended.
B. When disassembly is necessary, replace all O-rings and gaskets.
Replacement of other items should be guided by sound examination
criteria, see Check section.
C. The working area should be covered with clean carpeting or other suit-
able material and be free of hardware, tools, and sharp projections. Do
not stand or walk on the inflatable.
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3. Remove Slide Assembly From Valise (Figure 301) (IPL Figure 1)

WARNING: TO PREVENT EQUIPMENT DAMAGE AND INJURY TO
PERSONNEL, EXERCISE EXTREME CARE WHEN DIS-
CONNECTING THE PULL HANDLE ASSEMBLY (170)
ON A NON-DEPLOYED SLIDE, SINCE THE RESERVOIR
AND VALVE IS ARMED AND CHARGED; DO NOT PULL
OR OTHERWISE TENSION THE GIRT BEFORE THE
PULL HANDLE AND VALVE RELEASE CABLE IS DIS-
CONNECTED.
WARNING: TO PREVENT INJURY TO PERSONNEL, THE QUICK
DISCONNECT FITTING (250, 270) MUST REMAIN WITH
THE HANDLE ASSEMBLY SO THAT THE VALVE
RELEASE CABLE CANNOT SNAG AND CAUSE AN
INADVERTANT GAS DISCHARGE FROM THE RESER-
VOIR AND VALVE.
A. Disconnect the valve release cable assembly from the pull handle
assembly (170) at the quick disconnect fitting (250, 270).
VALVE RELEASE CABLE
SLIDE ASSEMBLY
DISCONNECT
BODY
SLEEVE
TO PULL
HANDLE
DETACHABLE GIRT
PULL HANDLE
DISCONNECT VALVE RELEASE CABLE

FIGURE 301
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3. Removal of Slide Assembly From Valise (Cont’d) (Figure 302) (IPL Figure 1)
B. Separate top and bottom halves of detachable girt by disengaging Vel-
cro fasteners.
C. Remove the shank end of the valve release assembly from the grom-
mets in the top and bottom half of the detachable girt assembly.
SLIDE ASSEMBLY
GROMMETS
DETACHABLE GIRT
VELCRO
CLOSURES
VALVE RELEASE
CABLE
(SHANK END)
REMOVE VALVE RELEASE CABLE ASSEMBLY FROM

DETACHABLE GIRT ASSEMBLY
FIGURE 302
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3. Removal of Slide Assembly From Valise (Cont’d) (Figure 303)

(IPL Figure 1)
D. Cut breakaway tie on warning flag, and remove the pull handle assem-
bly (170) from the girt (Velcro attachment).
PULL HANDLE
ASSEMBLY
VELCRO ATTACHMENT
REMOVE THE PULL HANDLE ASSEMBLY

FIGURE 303
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E. Separate the Velcro closure on the valise and fold back the top half of
the valise (120).
VALISE (TOP HALF)
PACKED SLIDE
VELCRO CLOSURE (6)

VALISE (BOTTOM HALF)
OPEN VALISE
FIGURE 304
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F. Unloop the light activating lanyard assembly (320, 320A) from the
retaining patch on the slide body.
LOOP RETAINING POWER UNIT

PATCH
LIGHT LANYARD
ASSEMBLY
SLIDE
ASSEMBLY
LOOPED END
UNLOOP THE LIGHT ACTIVATING LANYARD ASSEMBLY

FIGURE 305
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G. Coil and tape the valve release cable to the cable guide tube (50).
VALVE RELEASE
CABLE
CABLE GUIDE
TUBE
TAPE
(TABLE 301)
RETAINER VALVE RELEASE CABLE

FIGURE 306
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H. Disengage Velcro fasteners and remove the reservoir restraint.
RESERVOIR AND
VALVE ASSEMBLY
RESERVOIR RESTRAINT
SEPARATED AND
FOLDED BACK
SEPARATE RESERVOIR RESTRAINT FLAPS

FIGURE 307
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I. Lift folded slide (10), remove from valise assembly (120). Place folded
slide on work surface.
RESERVOIR
AND VALVE
FOLDED
SLIDE
VALISE ASSEMBLY
REMOVAL OF FOLDED SLIDE FROM VALISE

FIGURE 308
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4. Remove Detachable Girt Assembly (Figure 309) (IPL Figure 1)
A. Disengage Velcro and fold back girt release cover flap to expose cord
loops.
B. Disconnect detachable girt assembly (150) from slide assembly by
pulling the girt release cable handle (70).
NOTE: If slide is not inflated or at low pressure, the girt loops at the
upper and lower attachments must be loosened to effect
release.
GIRT RELEASE
HANDLE
SLIDE ASSEMBLY
GIRT RELEASE
CORD LOOPS
COVER FLAP
GIRT ASSEMBLY
REMOVAL OF DETACHABLE GIRT ASSEMBLY

FIGURE 309
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5. Removal of Mooring Line Assembly (Figure 310) (IPL Figure 1)
A. Untie mooring line (90) from detachable girt (150).

B. Remove mooring line from its storage pocket.
GROMMET
ATTACHMENT
STRIPS
DETACHABLE
GIRT
STORAGE POCKET
MOORING LINE
REMOVAL OF MOORING LINE ASSEMBLY

FIGURE 310
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6. Removal of Reservoir and Valve Assembly (Figure 311) (IPL Figure 1)
A. Unsnap and remove retaining strap from around the neck of reservoir.
B. Remove reservoir and valve assembly (180, 180A) from the reservoir
sling.
RESERVOIR AND VALVE

ASSEMBLY
RESERVOIR SLING
RETAINING STRAP
REMOVAL OF RESERVOIR AND VALVE ASSEMBLY

FIGURE 311
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7. Removal of Cable Guide Tube (Figure 312) (IPL Figure 1)
A. Remove tape from cable guide nut (60).

WARNING: TO PREVENT EQUIPMENT DAMAGE AND INJURY TO
PERSONNEL, EXERCISE EXTREME CARE WHEN DIS-
CONNECTING THE CABLE GUIDE TUBE FROM
VALVE/REGULATOR ASSEMBLY SINCE THE RESER-
VOIR AND VALVE MAY BE CHARGED AND ARMED.
B. Uncoil valve release cable.
C. Loosen cable guide nut (60).
D. Remove cable guide tube (50) from valve/regulator assembly.
E. Tape the release cable to the valve/regulator assembly.
VALVE/REGULATOR ASSEMBLY
TAPE
CABLE GUIDE
TUBE
VALVE RELEASE CABLE
NUT
REMOVAL OF CABLE GUIDE TUBE

FIGURE 312
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8. Removal of Power Unit (Figure 313) (IPL Figure 1)
A. Disconnect lamp harness (30C) per Detail “B” from power unit (200)
connectors.
RESERVOIR
SLING
POWER UNIT
POWER UNIT
HOLDER
LANYARD
LOOP
LANYARD PIN
POWER UNIT CONNECTORS

TEST LEAD
DETAIL “B”
LAMP HARNESS CONNECTORS
REMOVAL OF POWER UNIT

FIGURE 313
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9. Unfold Slide (Figure 314) (IPL Figure 1)
A. Unsnap the intermediate restraint and disengage end of frangible link

(160).
B. Separate the Velcro closure of the intermediate restraint sheath and
disengage opposite end of frangible link (160).
DISENGAGE FRANGIBLE LINK FROM

INTERMEDIATE RESTRAINT
REMOVAL OF FRANGIBLE LINK

FIGURE 314
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9. Unfold Slide (Cont’d) (Figure 315) (IPL Figure 1)

C. Partially unfold the slide assembly (10).
D. Disengage the rail positioners (secondary restraints).
E. Unfold remainder of slide.
SEE DETAIL “A”
UNFOLD
SEE DETAIL “A”
FEMALE
SECONDARY RESTRAINT
DETACHABLE
GIRT ASSEMBLY
DETAIL “A”
MALE
SECONDARY RESTRAINT
UNFOLD SLIDE
FIGURE 315
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This page is intentionally left blank.
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10. Removal of Aspirator Assembly (Figure 316) (IPL Figure 1)
WARNING: DEFLATE SLIDE BEFORE REMOVING ASPIRATOR TO

PROTECT PERSONNEL FROM POSSIBLE INJURY.
A. Remove tape from hose fitting and disconnect the hose (40A, 40B)
from the aspirator (230).
B. Remove tape from aspirator worm drive clamp (210).
C. Loosen worm drive clamp screw.
D. Remove clamp (210) from rubber mounting flange.
REMOVE TAPE
CLAMP
WORM DRIVE
CLAMP
REMOVE TAPE
HOSE
ASPIRATOR
REMOVAL OF CLAMP AND HOSE

FIGURE 316
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10. Removal of Aspirator Assembly (Cont’d) (Figure 317) (IPL Figure 1)

CAUTION: DO NOT DAMAGE ASPIRATOR RUBBER MOUNTING
FLANGE SEALING SURFACE.
E. Remove aspirator (230) from the aspirator mounting flange.
MOUNTING FLANGE
ASPIRATOR
REMOVAL OF ASPIRATOR FROM SLIDE

FIGURE 317
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11. Removal of Pressure Test Valve (Figure 318) (IPL Figure 1)
A. Remove cap.
B. Insert tool (Table 301); twist counter-clockwise to remove pressure test
valve core (242).
ASPIRATOR
VALVE STEM
VALVE CORE
TOOL
PRESSURE TEST
VALVE CORE
CAP
DISASSEMBLY OF PRESSURE TEST VALVE

FIGURE 318
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12. Removal of Relief Valve (Pre S.B. 737 103-25-31) (Figure 319) (IPL Figure 1)
A. Remove relief valve (220) from the valve flange using relief valve tool
(Table 301).
B. Remove gasket from relief valve.
RELIEF VALVE
GASKET
VALVE FLANGE
REMOVAL OF RELIEF VALVE

FIGURE 319
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13. Removal of Relief Valve (Post S.B. 737 103-25-31) (Figure 320) (IPL Figure 1)
A. Unscrew relief valve (220A) from the valve flange using

removal/installation tool (Table 301).
REMOVAL/INSTALLATION
TOOL
HANDLE
RELIEF VALVE
GASKET
VALVE FLANGE
RELIEF VALVE DISASSEMBLY

FIGURE 320
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TABLE OF CONTENTS
CLEANING
Page
1. Cleaning Materials 402
3. Slide Assembly 403
4. Valise or Detachable Girt 404
5. Pull Handle Assembly, Girt Release Cable 404
6. Aspirator Assembly 405
7. Worm Drive Clamp, Quick Disconnect 405
8. Hose Assembly 405
9. Relief Valve, Cable Guide Tube 406
10. Lamp Harness Assembly 406
Page 401
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1. Cleaning Materials (Table 401)

with the following symbol 


Fabric Cleaning Solution As Commercially Moderate cleaning of
Moderate Duty: Required Available fabric surfaces.
Clear Ivory Hand Washing
Fabric Cleaning Solution As Commercially Heavy duty cleaning
Heavy Duty: Required Available of fabric surfaces.
50% Isopropyl Alcohol
((CH3)2CHOH) and
50% Toluene (C6H5CH3)
by Volume
Cleaning Solvent for Metal As Commercial Cleaning of metal
Parts: Required Standard surfaces.
MIL-PRF-680 or
Clear Mineral Spirits 
Clean Soft Cloth  1 Commercially Application of solu-
Available tions/solvent; drying.
Stiff Bristle Brush  1 Commercially Application of solu-
Available tions/solvents.
Soft Bristle Brush  1 Commercially Application of solu-
Available tions/solvents.
CLEANING MATERIALS
TABLE 401
Page 402
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A. Observe all shop safety precautions and practices.
WARNING: WHEN USING SOLVENTS, CEMENTS, OR OTHER
CHEMICAL BASED PRODUCTS, REFER TO THE
APPLICABLE MATERIAL SAFETY DATA SHEET
(MSDS) FOR SPECIFIC GUIDELINES ON PROPER
PERSONAL PROTECTIVE EQUIPMENT, STORAGE,
HANDLING, AND VENTILATION REQUIREMENTS TO
PREVENT SICKNESS OR INJURY TO PERSONNEL.
CAUTION: WHEN WASHING THE SLIDE OR SLIDE/RAFT FABRIC,
DO NOT ALLOW EXCESS SOLVENT TO COLLECT AT
EDGES OF SEAMS. AVOID WASHING OVER DECALS
OR STENCIL MARKINGS (WHEN POSSIBLE) AS THEY
WILL BE REMOVED BY THE SOLVENT.
WARNING: TO PREVENT POSSIBLE INJURY, ENSURE AIR NOZ-
ZLE IS POSITIONED AWAY FROM BODY OR OTHER
PERSONNEL. MAKE SURE A 30 PSIG (20.7 N/CM2), OR
LESS, AIR NOZZLE IS ATTACHED TO AIR HOSE.
B. The shop compressed air source for drying purposes should be free of
oil and moisture and incorporate a 20 micron filter.
3. Slide Assembly
A. For removal of light to moderate concentrations of dust and dirt on slide
tube chambers and anti-skid compound areas, use a solution of deter-
gent (Table 401) and water.
(1). Apply solution with a soft bristle brush (Table 401) or a clean
cloth.
(2). Thoroughly rinse with clean water and blow dry with compressed
air.
B. For removal of heavy concentrations of dirt and grease on the slide
tube chambers and anti-skid compound areas, use the cleaning solu-
tion (Table 401).
CAUTION: DO NOT USE THE CLEANING SOLUTIONS MEK OR
ETHYL ACETATE ON ANTI-SKID COMPOUND AREAS,
OR COATING MAY BE REMOVED.
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CAUTION: DO NOT ALLOW PUDDLING OR DRIPPING OF SOLU-

TION, AS LIFTING OF CEMENTED AREAS MAY
RESULT.
(1). Apply solution with a clean, soft cloth or a soft bristle brush (Table
401) for local areas of oil, dust, or dirt.
(2). Immediately remove excess solution with a clean cloth and dry
using compressed air.
4. Valise or Detachable Girt
A. For removal of light to moderate concentrations of dust and dirt, use a
solution of detergent (Table 401) and water.
(1). Apply solution with a soft bristle brush or clean cloth.
(2). Thoroughly rinse with clean water and blow dry with shop air.
B. For removal of heavy concentrations of dirt and grease, use the heavy
duty cleaning solution (Table 401).
CAUTION: DO NOT ALLOW PUDDLING OR DRIPPING OF THE
SOLUTION AS LIFTING OF CEMENTED AREAS MAY
RESULT.
(1). Apply solution with a clean soft cloth or soft bristle brush for local
areas of oil, dust, or dirt.
(2). Immediately remove excess solution with a clean cloth.
(3). Dry using compressed air.
5. Pull Handle Assembly, Girt Release Cable
A. For removal of light to moderate concentration of dust and dirt, use a
solution of detergent (Table 401) and water.
(1). Apply solution with a soft bristle brush or clean cloth.
air.
B. For removal of heavy concentrations of dirt and grease, use heavy duty
cleaning solution (Table 401).
(1). Clean pull handle assembly using cleaning solution (Table 401).
(2). Apply solution with a clean soft cloth or soft bristle brush for local
(3). Immediately remove excess solution with a cloth.
(4). Dry using compressed air.
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6. Aspirator Assembly
CAUTION: FLAPPER VALVES MUST BE OPENED AND CLOSED

SIMULTANEOUSLY TO PREVENT DAMAGE TO THE
POSITIVE CLOSING MECHANISM COMPONENTS.
A. Under normal conditions, internal and external surfaces may be
cleaned using compressed air; ensure that air directed through the
inlet fitting flows freely from all orifices in the nozzle assembly.
CAUTION: MINIMIZE ASPIRATOR CONTACT TIME WITH ALL
CLEANING AGENTS.
B. Under extreme conditions, clean external surfaces with cleaning sol-
vent (Table 401) and a soft bristle brush; clean internal surfaces with a
solution of detergent (Table 401) and water. Rinse with clean water.
Thoroughly blow dry with compressed air.
7. Worm Drive Clamp, Quick Disconnect
A. For removal of concentrations of dirt and grease, use the cleaning sol-
vent (Table 401).
(1). Apply solvent with clean soft cloth or soft bristle brush for local
(2). Immediately remove excess solvent with a clean cloth and dry
using compressed air.
8. Hose Assembly
CAUTION: INSTALL PROTECTIVE PLASTIC CAP/PLUG ON HOSE

FITTINGS.
A. Clean hose external surfaces using rag dampened in detergent
(Table 401) and water solution. Rinse with clean water.
B. Blow dry using compressed air.
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9. Relief Valve, Cable Guide Tube
A. Clean using a solution of detergent (Table 401) and water.

(1). Apply solution with a soft bristle brush or a clean cloth.
air.
10. Lamp Harness Assembly
A. Each lamp on the harness may be cleaned with a water (only) damp-
ened cloth.
B. Wipe lamps thoroughly with a clean dry cloth.
Page 406
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TABLE OF CONTENTS
CHECK
Page
1. System Check 502
2. Inflation Assembly Check 502
3. Visual Check: Slide Assembly 503
4. Visual Check: Detachable Girt Assembly 505
5. Visual Check: Girt Release Cable 507
6. Visual Check: Pull Handle Assembly and Quick Disconnect 508
7. Visual Check: Aspirator and Worm Drive Clamp 509
8. Visual Check: Hose Assembly 510
9. Visual Check: Valise Assembly 511
10. Visual Check: Power Unit and Lanyard 512
11. Visual Check: Cable Guide Tube and Nut 513
Page 501
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1. System Check
NOTE: Refer to Tables 501 through 509 for visual checking of the slide
assembly and related components.
NOTE: When the disposition is replace refer to the Disassembly sec-
tion for the disassembly of the component and to the Assembly
section for the assembly of the component.
A. The work area must be covered with a clean tarpaulin, carpeting, or
other protective material and must be clean and well lighted.
B. The check can be made without the aid of special optical devices,
unless otherwise indicated herein.
2. Inflation Assembly Check
A. Refer to the Reservoir and Valve Inflation Assembly Component Main-

tenance Manual 25-65-20 Assembly and Check sections for check and
verification of proper gas charge.
Page 502
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61621
3. Visual Check: Slide Assembly (Table 501)
COMPONENT CONDITION DISPOSITION
Tubes and floor fabric/ Cuts, tears, punctures, See Repair section. If
seams or abrasions; mark with beyond limits, call or con-
chalk if discrepant. sult your Zodiac Services
Representative for repair.
Inspection of seams on Return to Air Cruisers
effected slide assem- owned and operated Ser-
blies (S/N 1445A, vice Centers per S.B. 737
1446A, 1452A, 1453A, 103-25-38.
1455A through 1467A,
1470A through 1473A,
and 1475A through
1483A).
Inspect stencilled mark- Re-stencil.
ings for legibility and
correctness.
Restraints, mounting Check general condi- Re-cement lifted area.
patches, handles, Velcro tion, looseness or mal- See Repair section. For
and snap fasteners, function as applicable; replacement, call or con-
attachment patches, res- mark with chalk if dis- sult your Zodiac Services
ervoir sling, no-fail han- crepant. Representative.
dles, re-entry strap, etc.
Grommets Grommet attachment Replace. See Repair sec-
(tightness) or sharp pro- tion.
jections.
Frangible Links Wires exposed, frayed Replace frangible link per
cord loops, or broken applicable Folding Proce-
threads. dure (APPX-1) or
Assembly section.
VISUAL CHECK: SLIDE ASSEMBLY
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Relief Valve Leakage. If valve leaks at mounting

(Pre S.B. 737 103-25-31) See Testing section. patch or base, call or con-
Stripped threads or sult your Zodiac Services
cracked body. Representative for repair.
If valve leaks at center,
tighten valve (Table 801).
If leak is still present
replace relief valve. See
Assembly section.
Relief Valve Leakage. Discrepant If valve leaks at mounting
(Post S.B. 737 opening and closing patch or base, call or con-
103-25-31) pressures. See Testing sult your Zodiac Services
section. Representative for repair.
Damaged threads. If valve leaks at center,
tighten valve (Table 801).
If leak is still present
replace relief valve. See
Assembly section.
Mooring Line Assembly Cuts, torn stitching. Replace as necessary.
Lamp Harness Test system for opera- See Testing section.
Assembly tion. See Testing sec-
tion.
Lifts or tears of the fabric Re-cement lifted areas.
tape. Loose lamp har- Replace tape as neces-
ness. sary. See Repair section.
Replace lamp housing.
Broken or burned out Replace lamp housing.
light. See Repair section.
Loose or broken wires or Replace lamp harness
any damage which assembly, see Repair
would impair function section.
VISUAL CHECK: SLIDE ASSEMBLY
Page 504
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4. Visual Check: Detachable Girt Assembly (Table 502)
Detachable Girt Minor cuts or tears that See Repair section.

Assembly do not intersect seams,
hinge tapes, or rein-
forcements.
Tears that intersect or Replace.
overlap hinge tapes or
reinforcement webbing.
Tears that run parallel to Replace.
the reinforcement web-
bing along the girt
perimeter.
Worn or broken threads Machine sew using V-T-
on seams, turn backs, 295 size “F” or A-A-
loose Velcro fasteners or 59826 size “F” nylon
webbings. thread in accordance
with Federal Specifica-
tion 751 Type 301 or Air
Cruisers P/N M11944-1.
Chafing on outer surface Add chafing patches per
near girt bar sleeve end. S.B. 737 103-25-32
Grommet attachment Replace. See Repair
(tightness) or sharp pro- section.
jections.
VISUAL CHECK: DETACHABLE GIRT ASSEMBLY
TABLE 502
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61621
Detachable Girt Torn or worn cord loops. Machine sew using V-T-
Assembly (Cont’d) 295 size “F” or A-A-
59826 size “F” nylon
thread in accordance
with Federal Specifica-
tion 751 Type 301 or Air
Cruisers P/N M11944-1
or, call or consult your
Zodiac Services Repre-
sentative for repair or
girt replacement.
Coating abrasion, flak- Re-coat. See Repair
ing, or exposure of section.
threads.
VISUAL CHECK: DETACHABLE GIRT ASSEMBLY
TABLE 502
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5. Visual Check: Girt Release Cable (Table 503)
Girt Release Cable Frayed cable, damaged Replace.

nicopress sleeve and/or
parachute pin. Sharp
projections.
VISUAL CHECK: GIRT RELEASE CABLE
TABLE 503
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61621
6. Visual Check: Pull Handle Assembly and Quick Disconnect (Table 504)
Pull Handle Assembly Hook fastener damaged, Replace.

cable frayed, or ball end
of cable not uniform.
Unreadable printed Replace.
material.
Fraying, cuts, or tears, of Replace.
webbing or Velcro.
Quick Disconnect Cross-threading and/or Replace.
attachment groove
deformity.
VISUAL CHECK: PULL HANDLE ASSEMBLY AND QUICK DISCONNECT
TABLE 504
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61621
7. Visual Check: Aspirator and Worm Drive Clamp (Table 505)
Aspirator Housing is not concen- Replace aspirator.

tric.
Cracks, cross-thread- Replace aspirator.
ing, or stripping of
threaded fittings.
Pressure test valve Replace pressure test
leaks at base. valve.
Pressure test valve Replace valve core.
leaks at stem.
Positive closing device Replace aspirator.
malfunction.
Excessive compression Replace aspirator.
or damage to the flapper
valve sealing surface.
Delamination.
Aspirator ring guards Replace aspirator.
bent or damaged.
Worm Drive Clamp Stripped worm drive Replace.
clamp screw.
Cracks, concentricity, or Replace.
sharp edges.
VISUAL CHECK: ASPIRATOR AND WORM DRIVE CLAMP
TABLE 505
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61621
8. Visual Check: Hose Assembly (Table 506)
Hose Assembly Cracks or damage to Replace.

hose fittings or threads.
Perform a hydrostatic If the hose fails the
test to 900 psig hydrostatic test, replace.
(620.5 N/cm2). See
Testing section.
Hose does not swivel Replace.
through 360°.
Obstructions in I. D. of Replace.
hose caused by bulging
or damage to inner liner.
Obstructions in I. D. of Remove obstructions
hose caused by foreign using compressed air.
matter/dirt. Determine source of for-
eign matter prior to
returning system to ser-
vice.
VISUAL CHECK: HOSE ASSEMBLY
TABLE 506
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9. Visual Check: Valise Assembly (Table 507)
Valise Assembly Rips, tears, or loose Repair small areas by

stitching of fabric. machine sewing and/or
cemented patches. See
Repair section.
Loose or damaged hook Replace as necessary.
and pile fasteners. See Repair section for
cementing instructions.
VISUAL CHECK: VALISE ASSEMBLY
TABLE 507
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61621
10. Visual Check: Power Unit and Lanyard (Table 508)
Power Unit Test System for opera- See Testing section.

tion.
Damaged plug connec- Replace.
tors. Loose or broken
wires.
Check expiration date. Ensure sufficient life
Usable life, 5 years from remains to meet or
date of manufacture. exceed next scheduled
maintenance before re-
installing.
Activating Lanyard Check activating lan- Replace.
yard ON/OFF pin for
insecure attachment
and any damage which
would impair function.
VISUAL CHECK: POWER UNIT AND LANYARD
TABLE 508
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61621
11. Visual Check: Cable Guide Tube and Nut (Table 509)
Cable Guide Tube Cracks which would Replace.

impair function
Cable Guide Nut Cracks, crossthreading, Replace.
and stripping
VISUAL CHECK: CABLE GUIDE TUBE AND NUT
TABLE 509
Page 513, 13 Nov 2015

25-66-07 Page 514, Blank
61621
TABLE OF CONTENTS
REPAIR
Page
1. Repair Materials /Equipment 602
2. General Information - Limits (In Field) 607
3. Patching Airholding Tubes 610
4. Floor Repairs 624
5. Reflective Finish 625
6. Detachable Girt Assembly 627
7. Grommet Replacement 628
8. Individual Lamp Housing Replacement 632
9. Lamp Harness Replacement 638
10. Lamp Harness Replacement (S/N 1003A, 1004A through 1064A) 640
11. Lamp Harness Replacement (S/N 1065A and Subs) 650
12. Wire Guide Replacement 659
13. Replacement of Nylon Tube on Girt Bar 660
14. Girt Bar Replacement 664
Page 601
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61621
1. Repair Materials/Equipment (Tables 601 through 604)

with the following symbol

Urethane Cement As Air Cruisers Fabric bonding adhe-
Specification No. M11628 Required V70167 sive.
Solvent, Washing Urethane As Commercially Cleans fabric.
Ethyl Acetate Required Available
(CH3COOC2H5)
Activating Agent, Urethane As Commercially Activates urethane
Methyl Ethyl Ketone (MEK) Required Available cement for bonding.
(CH3COC2H5)
Activating Agent, Urethane As Commercially Activates urethane
Ethyl Acetate/Acetone Solu- Required Available cement for bonding.
tion
(CH3COOC2H5)/
(CH3COCH3) *
* Two parts Ethyl Acetate one part Acetone by volume; may be used as an alter-
native to Methyl Ethyl Ketone.
Toluene As Commercially Thinner for reflective
(C6H5CH3) Required Available coating compound.
Leak Test Solution As Commercially Determines leakage of
Clear Ivory Hand Washing Required Available inflatable assemblies.
One ounce (29.6 milliliters) of detergent mixed to every 64 ounces (1.9 liters) of
water.
Primer, PC4426 As Clifton Applied to nylon tube
Required Adhesive, Inc. on girt bar.
V79833
REPAIR SOLVENTS AND CEMENTS

TABLE 601
Page 602
25-66-07 13 Nov 2015
61621

with the following symbol

Hand Roller/Castor Wheel 1 Everhard Distributes pressure
MR02040 Products, Inc. along bonded fabric
(2 In. (50.8 mm) dia. x V72274 repairs.
2 In. (50.8 mm) wide with
handle) 
Brush, 1 Inch (25.4 mm)  1 Commercially Applies cement.
Available
Spatula (Pusher) 1 Air Cruisers Evenly distributes, and
PA-1  V70167 removes wrinkles from,
bonded fabric repairs.
Cloth, Cotton  As Commercially Applies solvents/solu-
Required Available tions.
Talc or Powdered Soap- As Commercially Prevents joining of
stone Required Available areas of exposed
cement, reflective
coating compound, or
stencil ink.
Sand Paper As Commercially Used prior to primer
220 Grit Required Available application.
Scissors, Blunt Nose, 1 Commercially Cuts fabric.
Plated, 5 Inch (127 mm)  Available
REPAIR TOOLS
TABLE 602
Page 603
25-66-07 13 Nov 2015
61621
NOTE: Variation in fabric color shades is normal and acceptable.


Stencil Ink As Air Cruisers Used for identification/
M11853 Required V70167 instruction markings.
Slide Fabric As Air Cruisers Inflatable sub-assem-
M11849-5 Required V70167 bly tube/chafing patch-
ing fabric.
Floor Fabric (Urethane) As Air Cruisers Inflatable sub-assem-
M11673 Required V70167 bly sliding lane or chaf-
ing fabric.
Girt Fabric As Air Cruisers Girt, Detachable Girt-
M11480 Required V70167 Girt and Girt exten-
sion fabric.
Valise Fabric As Air Cruisers Valise fabric.
M11481 Required V70167
Cord As Air Cruisers Used in lamp harness
M11972-2 Required V70167 installation and
removal.
Reflective Coating Compound As Air Cruisers Coating for accessible
M12159 Required V70167 seams, crotch tapes,
attaching surfaces of
cemented-on accesso-
ries, exposed threads,
and adhesive margins.
Brillo 3M Scotch Brite 1 Commercially Used to roughen floor
(Scour Cloth) Available fabric prior to cement-
7447 ing.
Tape, Black Fire As Air Cruisers Provides chafe protec-
Retardant Required V70167 tion from metal fittings.
1.0 In. (25.4 mm) wide
M12397-1 (Ref. S.I.L. 25-252)
REPAIR MATERIALS
Page 604
25-66-07 13 Nov 2015
61621

Drive Punch Pin 1 Commercially Removes roll pin from
1/8 Diameter Available nylon stop sleeve.
Sealant, Clear As Air Cruisers Applied as a non-slip
H119077 Required V70167 area where stabilizer
or sill tube makes con-
tact with aircraft; or as
a runway end deceler-
ation pad. Used dur-
ing girt repair.
Conductive Paint As Air Cruisers Provides conductivity
M11463 Required V70167 between girt, sliding
surface, and bottom
runway chafings. Used
during girt repair.
REPAIR MATERIALS
Page 605
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61621


Soldering Iron 600°-800° F 1 Commercially Heats solder for appli-
(315.6° - 426.7°C) Available cation.
Heat Range
Soldering Iron Tip 1 Commercially Melts mylar insulation.
Screwdriver or Chisel Tip Available
Soldering Iron Tip 1 Commercially Applies solder.
Conical or Pencil Tip Available
Solder As Commercially Alloy used to join
QQ-S-571 SN60/40Pb Required Available metal.
Rosin Core, Mildly Acti-
vated
Desoldering Bulb  1 Commercially Removes solder.
Vacuum Action, Teflon Tip Available
Marker  1 Commercially Traces outline of dam-
Black Ink, Permanent, Fine Available aged lamp housing
Tip ends.
Knife, Precision Blade  1 Commercially Removes heat shrink
Available coverings from lamp
housings.
Shield, Wood  1 Commercially Protects fabric from
1/4 x 12 x 12 In. Available soldering iron.
(6.4 x 304.8 x 304.8 mm)
(Approximate dimensions)
Pliers, Slip-Lock  1 Commercially Breaks ultra-sonic
1 1/2 In. (38.1 mm) opening Available welds.
min.
Magnifier, Eye Loupe 1 Commercially Used for precise exam-
10X power  Available ination of lamp hous-
ing.
LAMP REPLACEMENT REPAIR MATERIALS

Page 606
25-66-07 13 Nov 2015
61621

Isopropyl Alcohol As Commercially Removal of solder flux
((CH3)2CHOH) Required Available from solder joints.
Brush, small stiff bristles  1 Commercially Solvent/solution appli-
Available cator.
Bottle, Dispensing, with 1 Commercially Solvent/solution dis-
spout or pump  Available penser.
Tape, Mylar As Commercially Used to wrap solder
3/8 In. (9.5 mm) wide, Required Available joints and flat conduc-
2 mils (.002 In.) thick tors.
LAMP REPLACEMENT REPAIR MATERIALS

Page 607
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61621
2. General Information - Limits (In Field)
NOTE: If doubt exists as to the capability of local facilities to accom-

plish satisfactory repairs, it is recommended that the inflatable
or components be returned to a Zodiac Services Repair Cen-
ter for repair (reference S.I.L. 25-102).
A. In general, repairs to the inflatable will be confined to the patching of
tears or punctures in the airholding panels. Although slightly damaged
areas in the fabric can be repaired in the field, replacement of a com-
plete section such as a tube, the floor, etc., should not be attempted,
since the operating integrity of the inflatable could be compromised.
The same rule applies to the removal of any part cemented directly to
an air-retaining fabric member, since in removal from the original posi-
tion, the fabric coating may be damaged, thus compromising air-reten-
tion capabilities. Slight lifting of any part such as restraint patches,
wraparound band, etc., cemented directly to an air-retaining fabric
member may be repaired per the general cement instructions detailed
in Paragraphs 3.A.(2) through (11). A seam separation without fabric
tears on or about the area may also be repaired per the general
cement instructions detailed in Paragraphs 3.A.(2) through (11). Call or
consult your Zodiac Services Representative for repair of any seam
tears that intersect a mitered corner.
CAUTION: WHEN INSPECTING FOR LEAKS, USE LEAK TEST
SOLUTION (TABLE 601) OR AN ELECTRONIC LISTEN-
ING DEVICE.
B. Following repairs to the airholding tubes, an inflatable integrity verifica-
tion test must be accomplished. See Testing section.
NOTE: Subsequent to repair, wash off leak test solution with clean
water.
Page 608
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61621
C. Facility Conditions for Repairs

(1). Work areas used for cementing must be clean, free of dust and
dirt.
CAUTION: COLD TEMPERATURES WHERE DEW OR FROST IS
PRESENT CAN CAUSE A PROBLEM OF MOISTURE ON
THE FABRIC, WHICH WOULD PROHIBIT PROPER
BOND FROM BEING MADE. HIGH HEAT AND/OR
HUMIDITY CAN RESULT IN EFFECTS OF CONDENSA-
TION OF MOISTURE (WHITE AREAS ON CEMENT)
CAUSED BY EVAPORATING SOLVENTS.
(2). Recommended temperature to apply the cement should be
between 55 - 80°F (13 - 27°C) with relative humidity (65% maxi-
mum).
D. Cement/Accelerator Storage
(1). Cement/Accelerator shall be stored under conditions where
excessive heat, humidity or cold are not present. Once opened, if
the accelerator is exposed to moisture present in high humidity
areas, it will cause flake like particles in the product. Accelerator
should not be used if flake like particles are present indicating
degradation. It is suggested to use what is opened, because re-
sealed containers may contain enough moisture to react with the
accelerator.
E. Mixing Instructions for Reflective Paint
(1). M12159 is supplied in two parts in order to maintain a workable
shelf/pot life. Prior to use, it is important to thoroughly mix the two
components. The base component (Part A) should be stirred/agi-
tated to ensure that the ingredients are homogeneous. Note that
settling does occur and the product must be uniform prior to use.
Part B takes additional care when mixing. The aluminum portion
forms a paste-like consistency on the bottom of the container. To
mix properly, this product should be agitated and then stirred.
Once no sedimentation is observed, a proper mix has occurred.
At this point, the two components should be combined to the
proper ratio. Any combined unused portions shall be disposed of
on a daily basis.
Page 609
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61621
3. Patching Airholding Tubes
A. Tube Punctures up to 2 In. (50.8 mm) in diameter.

NOTE: Use a round patch on the outer fabric surface only. Repair
patches should be die cut, when size permits.
(1). Cut a patch large enough to allow an overlap beyond the punc-
ture edges as follows:
Minimum Overlap Beyond

Puncture Limits Damaged Area Should Be:
Up to 1/8 In. (3.2 mm) 1 In. (25.4 mm)
1/8 to 1 In. (3.2 to 25.4 mm) 2 In. (50.8 mm)
Over 1 In. but less than 2 In. (25.4 to 50.8 mm) 3 In. (76.2 mm)
CAUTION: WHEN WASHING THE TUBE FABRIC, DO NOT ALLOW

EXCESS SOLVENT TO COLLECT AT THE EDGES OF
SEAMS. DO NOT APPLY SOLVENT TO DECALS OR
STENCIL MARKINGS (WHENEVER POSSIBLE) SINCE
THEY CAN BE REMOVED BY THE SOLVENT. IF STEN-
CIL MARKINGS NEED TO BE REPLACED, USE THE
STENCIL INK LISTED IN TABLE 603.
(2). Thoroughly wash the fabric around the puncture and the yellow
side of patch (Table 603) with a cloth dampened in solvent (Table
601). Do not damage the fabric.
Page 610
25-66-07 13 Nov 2015
61621
TUBE
WASH BOTTOM FABRIC
OF PATCH
PUNCTURE IN
WASH AREA TUBE FABRIC
AROUND PUNCTURE
PATCHING TUBE PUNCTURES

FIGURE 601
Page 611
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61621
CAUTION: DISCARD UNUSED CEMENT 4 HOURS (POT LIFE)

AFTER MIXING.
NOTE: The cement line must be even and uniform to within one-half
inch beyond the edge of repair.
(3). Brush three coats of cement (Table 601) around the puncture and
onto yellow side of the patch (Figure 602); cover an area slightly
larger than the patch. Apply cement in medium, even coats. Allow
15 minutes drying time between coats. Remove effects of con-
densation (white areas on cement) by swabbing with a cloth
lightly dampened in solvent (Table 601).
CEMENT BOTTOM OF PATCH (3 COATS)
TUBE FABRIC BRUSH
CEMENT AREA AROUND

PUNCTURE (3 COATS)

FIGURE 602
Page 612
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61621
CAUTION: DO NOT EXCEED ONE HOUR BETWEEN CEMENT

APPLICATION AND JOINING OF SURFACE. APPLY A
FOURTH COAT TO SURFACES IF TIME IS EXCEEDED.
(4). Within one hour after cement application, dampen a clean cloth
with activating agent (Table 601). Wipe cemented surfaces to
make them tacky and ready for joining.
NOTE: Fabric weave on patch and tube fabric do not have to be in
alignment.
CAUTION: JOIN SURFACES IMMEDIATELY (WITHIN 60 SECONDS)
AFTER ACTIVATING TO MAXIMIZE BOND.
(5). Immediately join the cemented patch to the cemented tube fabric.
(6). The patch should be laid on gradually from the center to the
edges (Figure 603) to minimize the possibility of air bubbles being
trapped beneath the patch.
TUBE
FABRIC
PATCH
CEMENTED AREA
CENTER LINE OF
CEMENTED AREA

FIGURE 603
Page 613
25-66-07 13 Nov 2015
61621
NOTE: Pressure is important for a good bond.

(7). Apply pressure evenly with a spatula (Table 602) to eliminate
entrapped air bubbles and wrinkles to ensure firm attachment
(Figure 604).
(8). When all wrinkles and air bubbles are eliminated, uniformly roll
the joined areas (Figure 605) using a hand roller (Table 602).
SPATULA
(PUSHER)
PATCH
TUBE
FABRIC

FIGURE 604
HAND ROLLER
PATCH
TUBE
FABRIC

FIGURE 605
Page 614
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61621
(9). Allow cement to cure for a minimum of four hours.

(10). If the repair has been performed on an airholding tube, perform
inflatable integrity verification tests. See Testing section.
(11). Apply reflective finish to the repaired area per the instructions in
Paragraph 5.
B. Repair of Tube Tears [Up to 2 Ft. (.610 m)]
Repairs to tube fabric tears should be limited to 2 Ft. (.610 m) maxi-
mum, if the tear does not intersect a seam or a miter joint. If these are
part of the tear, then call or consult your Zodiac Services Representa-
tive for repair.
CAUTION: REPAIR TUBE TEARS BY PATCHING BOTH THE INSIDE
AND OUTSIDE SURFACES OF THE TUBE FABRIC
PRIOR TO INFLATING THE UNIT.
(1). Trim off any loose threads (Figure 606) with scissors (Table 602).
SCISSORS TO TRIM
OFF LOOSE THREADS
TEAR IN FABRIC
PATCHING TUBE TEARS

FIGURE 606
Page 615
25-66-07 13 Nov 2015
61621
(2). Spread a handful of soapstone or talc (Table 602) inside the tube
opening on the tube fabric opposite the tear area (Figure 607) to
prevent joining the inside of the fabric together.
TRIMMED TEAR
IN FABRIC
HANDFUL OF
SOAPSTONE
PATCHING TUBE TEARS

FIGURE 607
(3). Cut a patch large enough to allow a 2 In. (50.8 mm) overlap
beyond the tear edges.
CAUTION: WHEN WASHING THE TUBE FABRIC, DO NOT ALLOW
EXCESS SOLVENT TO COLLECT AT EDGES OF
SEAMS. DO NOT APPLY SOLVENT TO DECALS OR
STENCIL MARKINGS (WHENEVER POSSIBLE) SINCE
THEY CAN BE REMOVED BY THE SOLVENT.
Page 616
25-66-07 13 Nov 2015
61621
(4). Thoroughly wash the inside surface of the fabric around the tear
(Figure 608) and the underside of the patch with a cloth damp-
ened in solvent (Table 601).
TUBE FABRIC
CLOTH DAMPENED
TEAR IN SOLVENT
PATCHING TUBE TEARS

FIGURE 608
CAUTION: DO NOT EXCEED ONE HOUR BETWEEN CEMENT

APPLICATION AND JOINING OF SURFACE. APPLY A
FOURTH COAT TO SURFACES IF TIME IS EXCEEDED.
CAUTION: DISCARD UNUSED CEMENT 4 HOURS (POT LIFE)
AFTER MIXING.
(5). Brush three coats of cement (Table 601) on the inside surface of
the tube fabric. Cover an area slightly larger than the size of the
patch. Apply cement in medium, even coats. Allow 15 minutes
between coats. Remove effects of condensation (white areas on
cement) by swabbing with a cloth lightly dampened in solvent
(Table 601).
(6). Thoroughly wash the inside surface of the fabric patch with a
cloth dampened in solvent (Table 601). Do not damage the fabric.
Page 617
25-66-07 13 Nov 2015
61621
(7). Brush three coats of cement (Table 601) onto the patch. Apply
cement in medium, even coats. Allow 15 minutes between coats.
Remove effects of condensation (white areas of cement) by
swabbing with a cloth lightly dampened in solvent (Table 601).
AFTER ACTIVATING TO PREVENT INADEQUATE BOND.
(8). Within one hour after the cement application, dampen a clean
cloth with activating agent (Table 601). Wipe cemented surfaces
to reactivate them. This brings up the tack and makes the sur-
faces ready for joining.
(9). Fold the patch in half lengthwise, pass it through the tear, and
install it cement side up on the inside surface of the tube fabric
directly under the tear (Figure 609).
TRIMMED
TEAR
HALF OF PATCH
LOCATED UNDER HALF
OF TRIMMED TEAR
WASH/CEMENT (3 COATS)
ACTIVATION AREA OF PATCH
PATCHING TUBE TEARS

FIGURE 609
Page 618
25-66-07 13 Nov 2015
61621
(10). Join the torn section of the tube fabric onto the patch per
Figure 609.
NOTE: Pressure is important for a good bond.
entrapped air bubbles and wrinkles to ensure firm attachment.
(12). When all wrinkles and air bubbles are eliminated uniformly roll the
joined areas (Figure 610) using a hand roller (Table 602).
HAND ROLLER
TUBE FABRIC
PATCHING TUBE TEARS

FIGURE 610
Page 619
25-66-07 13 Nov 2015
61621
(13). Cut a patch large enough to allow a 2 In. (50.8 mm) overlap
beyond the tear edges.
CAUTION: WHEN WASHING THE TUBE FABRIC, DO NOT DAM-
AGE THE FABRIC, DO NOT ALLOW EXCESS SOLVENT
TO COLLECT AT THE EDGES OF THE SEAMS. DO NOT
APPLY SOLVENT TO DECALS OR STENCIL MARKINGS
(WHENEVER POSSIBLE) SINCE THEY CAN BE
REMOVED BY THE SOLVENT.
(14). Thoroughly wash the outside surface around the tear (Figure
611) with a cloth dampened in solvent (Table 601).
TUBE FABRIC
CLOTH DAMPENED
IN SOLVENT
CEMENTED AREA
PATCHING TUBE TEARS

FIGURE 611
Page 620
25-66-07 13 Nov 2015
61621
(15). Brush three coats of cement (Table 601) on the outside of the
tube fabric (Figure 612) per the cement instructions detailed in
Paragraph 3.A.(3).
BRUSH
CEMENTED
TUBE FABRIC AREA
PATCHING TUBE TEARS

FIGURE 612
(16). Thoroughly wash the fabric on the patch with a cloth dampened in
solvent (Table 601). Do not damage the fabric.
(17). Brush three coats of cement (Table 601) onto yellow side of the
patch. Apply cement in medium, even coats. Allow 15 minutes
between coats. Remove effects of condensation (white areas of
cement) by swabbing with a cloth lightly dampened in solvent
(Table 601).
AFTER ACTIVATING TO PREVENT DRY AREAS.
(18). Within one hour after cement application, dampen a cloth with
activating agent (Table 601) and wipe cemented surfaces to reac-
tivate them. This brings up the tack and makes the surfaces ready
for joining.
NOTE: Fabric weave on patch and tube fabric do not have to be in
alignment.
Page 621
25-66-07 13 Nov 2015
61621
(19). Join the cemented surface of the patch to the outside surface of
the tube fabric (Figure 613).
entrapped air bubbles and wrinkles to ensure firm attachment.
(21). When all wrinkles and air bubbles are eliminated uniformly roll the
joined areas (Figure 614) using a hand roller (Table 602).
(22). Allow cement to cure for a minimum of four hours.
(23). If the repair has been performed on an airholding tube, perform
inflatable integrity verification tests. See Testing section.
(24). Apply reflective finish to the repaired area per the instructions in
Paragraph 5.
Page 622
25-66-07 13 Nov 2015
61621
PATCH LOCATED ON TOP

OF TRIMMED TEAR
PATCHING TUBE TEARS

FIGURE 613
HAND ROLLER
PATCH LOCATED
ON TOP OF
TRIMMED TEAR
PATCHING TUBE TEARS

FIGURE 614
Page 623
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61621
4. Floor Repairs
Repairs to the floor surface should be limited to punctures and tears up

to 3 In. (76.2 mm). If the damaged area exceeds these limitations, call
or consult your Zodiac Services Representative for repair.
A. Trim off loose threads with scissors (Table 602).
NOTE: Sliding surface of system is silver/gray in color, underside is sil-
ver in color. Install patch to the underside (silver side) of floor
surface.
B. Cut a patch of floor fabric (Table 603) large enough to allow an overlap
beyond the puncture per Paragraph 3.A.(1) or large enough to allow a
two inch overlap beyond the tear edges.
C. Buff patch, (silver/gray), and damaged area of floor fabric with Brillo 3M
Scotch Brite cloth (Table 603).
CAUTION: WHEN WASHING THE FLOOR FABRIC, DO NOT
ALLOW EXCESS SOLVENT TO COLLECT AT EDGES
OF SEAMS.
D. Thoroughly wash the floor fabric (silver side) around the damaged area
with a cloth dampened in solvent (Table 601).
E. Apply three coats of cement (Table 601) on the silver side of the floor
fabric per the general cement instructions detailed in Paragraph
3.A.(3).
F. Prepare the patch, silver/gray, with a cloth dampened in solvent (Table
601).
G. Apply three coats of cement (Table 601) on the silver/gray side of the
patch per general cement instructions detailed in Paragraph 3.A.(3).
AFTER ACTIVATING TO PREVENT INADEQUATE BOND.
H. Activate and join the patch to the floor fabric per the general cement
instructions detailed in Paragraphs 3.A.(4) through (9).
I. Apply reflective finish per Paragraph 5.
Page 624
25-66-07 13 Nov 2015
61621
5. Reflective Finish
A. Preparation of the fabric surface.

(1). Prior to applying the reflective finish, all dust, dirt, and grease are
to be removed from the surface to be coated using a cloth damp-
ened in solvent (Table 601).
(2). Remove excess solvent from all surfaces of the tube structures
with a dry cloth.
(3). The cleaned surface will require a minimum drying time of one
hour. Before proceeding further, verify that the surface is clean
and dry.
B. Coating Compound
CAUTION: THE COMPOUND MUST BE STIRRED PERIODICALLY
(EVERY 10 MINUTES) TO KEEP ALUMINUM PLATE-
LETS SUSPENDED IN THE SOLUTION. IF THE COAT-
ING THICKENS DURING APPLICATION, ADD
TOLUENE.
(1). The compound (Table 603) should be thoroughly mixed to ensure
that all of the pigments are evenly dispersed and suspended in
the solution.
(2). The coating should be a viscosity for brushing. Toluene (Table
601) may be added to maintain viscosity.
C. Inflatable Pressure During Coating
(1). After the cleaned surfaces have dried, the unit is to be inflated to
2.0 psig (1.4 N/cm2).
CAUTION: REWORKED AREAS MUST CURE FOR FOUR HOURS,
BE DUSTED WITH SOAPSTONE, AND BE ALLOWED
TO AIR DRY FOR A MINIMUM OF 16 HOURS BEFORE
DEFLATING AND PACKING.
Page 625
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61621
D. Application of Coating
(1). Apply the coating with a soft nylon brush (Table 602). Apply coat-
ing sparingly, brushing out all sags or drips. The repaired areas,
including exposed cement areas, are to be covered with one coat
using even strokes.
(2). Allow to cure for four hours, then dust lightly with soapstone or
talc (Table 602).
(3). Allow to air dry for a minimum of 16 hours before deflating and
packing.
Page 626
25-66-07 13 Nov 2015
61621
6. Detachable Girt Assembly
Repairs to the girt assembly should be limited to punctures, tears less

than 3 In. (76.2 mm), and to replacing grommets. If the damaged area
exceeds these limitations or occurs at or along the perimeter of the girt
assembly, call or consult your Zodiac Services Representative for
repair.
A. Detachable Girt Repair
(1). Follow the basic cementing instructions outlined in Paragraph 3.A
for punctures or tears, except use the detachable girt assembly
patching fabric (Table 603).
B. Recoating of Detachable Girt Assembly (Coating abrasion, flaking, or
exposure of threads).
CAUTION: IF ANY DAMAGE TO FABRIC SUBSTRATE IS NOTICED,
THE GIRT MUST BE REPLACED. CALL OR CONSULT
YOUR ZODIAC SERVICES REPRESENTATIVE FOR
REPLACEMENT INSTRUCTIONS.
NOTE: Use masking tape to control edges of coated areas.
(1). Before applying sealant, prepare fabric surface per Paragraphs 5.
A.(1) through (3).
(2). Apply three coats of sealant (Table 603) to girt fabric. Sealant
must be applied in well defined squared off areas (Figure 615).
Remove tape and discard. Allow sealant to dry 14 hours.
(3). Apply two coats of conductive paint (Table 603) over the entire
sealant area. The paint must overlap the sealant edges by
3/4 In. (19.1 mm) minimum. Allow four hours curing time.
CONDUCTIVE
PAINT APPLY SEALANT
TO WORN GIRT
MASKING TAPE
AREA
RECOAT GIRT FABRIC

FIGURE 615
Page 627
25-66-07 13 Nov 2015
61621
7. Grommet Replacement
NOTE: For grommet identification see Figures 618 and 619.

A. If the grommet is damaged, mark location, remove and discard grom-
met. Measure hole in fabric left by grommet.
NOTE: If the fabric is stretched, frayed, or cut around the grommet
hole, it may be necessary to cut a larger diameter fabric disc to
sufficiently cover the damaged area [at least 3/4 In. (19.1 mm)
larger]. Fabric disc will be cut from the same fabric as item to
be repaired.
B. Bond two fabric discs (Table 603), 3/4 In. (19.1 mm) in diameter larger
than the damaged area, to both the top side and underside of the area
to be repaired (Figure 616).
C. Brush three coats of urethane cement (Table 601) onto the disc, and
onto the area to be repaired.
D. Install the disc per Paragraphs 3.A.(3) through (9).
DISC
MISSING GROMMET FABRIC

(TOP)
DISC CEMENT AREA
DISC
GROMMET REPLACEMENT
FIGURE 616
Page 628
25-66-07 13 Nov 2015
61621
E. Allow the cement to cure for two hours minimum.

NOTE: Use an appropriate size punch for punching hole.
F. Punch a hole through fabric in marked location using an appropriate
size punch.
G. Install the grommet per Figure 617.
MALLET
PUNCH
GROMMET
(TOP)
PUNCHED HOLE
GROMMET
(BOTTOM)
GROMMET REPLACEMENT
FIGURE 617
Page 629
25-66-07 13 Nov 2015
61621
MS20230BS1 C587
(2 PLACES)
MS20230BS1
(TOP VIEW)
DETACHABLE GIRT (BOTTOM VIEW)
GROMMET IDENTIFICATION
FIGURE 618
Page 630
25-66-07 13 Nov 2015
61621
MS20230BS2
(8 PLACES)
GIRT ATTACHMENT, TOP
MS20230BS2
(8 PLACES)
MS20230BS1
GIRT ATTACHMENT, BOTTOM
GROMMET IDENTIFICATION
FIGURE 619
Page 631
25-66-07 13 Nov 2015
61621
8. Individual Lamp Housing Replacement (Figures 620 and 621)
NOTE: *Individual replacement lamps, P/N A3-06-0761-007, A3-06-

0761-008, A3-06-0195-102 and A3-06-0195-103 are no longer
being manufactured. Entire lamp harness must be replaced.
A. Lamp housing assemblies which fail to illuminate after system deploy-
ments, or testing shall be repaired per the following procedure. There is
no limit to the number of lamp assemblies which may be replaced on
any single lamp harness.
B. To determine the replacement lamp housing part number, examine the
lamp to be repaired and compare it with the illustrations in Figures 620
and 621.
2 1/8 In.
(54 mm)
A B A
B 1 1/16 In.
(27 mm)
SECTION A-A SECTION B-B
*A3-06-0195 -102 ASSEMBLY

Replacement Lamp Assembly, Channel, without Shield, Tubular Lamp
2 1/8 In.
(54 mm)
A SHIELD
B A
B 1 1/16 In.
(27 mm)
SECTION A-A SECTION B-B
*A3-06-0195 -103 ASSEMBLY

Replacement Lamp Assembly, Channel, with Shield, Tubular Lamp
REPLACEMENT LAMPS
FIGURE 620
Page 632
25-66-07 13 Nov 2015
61621
LAMP
.12 In. .12 In.

(3.0 mm) (3.0 mm)
6.0 ± 0.5 In. 6.0 ± 0.5 In.
(152.4 ± 12.7 mm) (152.4 ± 12.7 mm)
LAMP
A3-06-0761 -001 ASSEMBLY A3-06-0761 -004 ASSEMBLY

Replacement Lamp Assembly, Replacement Lamp Assembly,
Welded, without Porches, One T1 Lamp Welded, without Porches, Two T1 Lamps
PORCH
.12 In. .12 In.

(3.0 mm) (3.0 mm)
6.0 ± 0.5 In. 6.0 ± 0.5 In.
(152.4 ± 12.7 mm) (152.4 ± 12.7 mm)
A3-06-0761 -005 ASSEMBLY A3-06-0761 -006 ASSEMBLY

Welded, with Porches, One T1 Lamp Welded, with Porches, Two T1 Lamps
.12 In. .12 In.

(3.0 mm) (3.0 mm)
6.0 ± 0.5 In. 6.0 ± 0.5 In.
(152.4 ± 12.7 mm) (152.4 ± 12.7 mm)
*A3-06-0761 -007 ASSEMBLY *A3-06-0761 -008 ASSEMBLY

Welded, with Porches, Two LEDs Welded, with Porches, One Tubular Lamp
REPLACEMENT LAMPS
FIGURE 621
Page 633
25-66-07 13 Nov 2015
61621
8. Lamp Harness Housing Replacement (Cont’d)

C. Use repair materials in Table 604 to repair lamp housing.
D. Disconnect Lamp Harness from power supply.
E. Pull approximately 9 In. (228.6 mm) on either side of damaged lamp
assembly from the fabric light sleeve.
CAUTION: PROTECT SYSTEM FABRIC FROM BEING BURNED BY
SOLDERING IRON OR HOT SOLDER BY USING A NON-
ABRASIVE SHIELD AND DAMP PAPER TOWEL
BETWEEN SYSTEM AND LAMP HARNESS.
F. Use a small sharp knife to carefully remove all heat shrink coverings on
the existing lamp housing (see Figure 622).
G. Use an indelible black marker to trace the outline of the ends of the
lamp housing containing the damaged lamp. These outlines will be
used to help locate the replacement lamp housing assembly.
NOTE: It is important to position replacement lamp housing in the
same location as the existing housing.
H. Use a pair of slip lock pliers (Table 604) to break the ultrasonic welds
between the upper and lower housing halves. Separate using a flat
head screw driver.
CAUTION: EXCESSIVE HEAT FROM SOLDERING IRON CAN DAM-
AGE FLAT CONDUCTOR.
I. Remove the lamp by desoldering. Use an appropriate solder remover
to eliminate any protruding solder approximately 600°F (315.6°C).
J. Remove the reflector.
K. Overlay the replacement lamp housing assembly on the existing flat
conductor, position the replacement lamp housing so that the black
marker tracings are aligned with the new housing.
L. Mark the location of the exposed tin plated copper conductor of the
replacement lamp housing on the existing flat conductor (4 places).
Page 634
25-66-07 13 Nov 2015
61621
NOTE: Visually examine each tin plated copper conductor to verify

that the mylar has been completely removed.
M. Using a soldering iron (Table 604) with a screw driver or chisel tip,
carefully melt away the upper layer of mylar insulation for approxi-
mately 3/8 In. (9.5 mm) over each tin plated copper conductor on the
existing flat conductor where marked.
NOTE: Visually verify that the solder has not bridged or shorted the tin
plated copper conductors.
N. Deposit a small amount of solder on each of the four exposed tin plated
copper conductors on the existing flat conductor using a soldering iron
with a conical soldering tip.
O. Position the replacement lamp housing assembly over the existing flat
conductor, hold in position, and solder the replacement lamp housing
assembly to the existing flat conductor using a conical soldering tip.
NOTE: Assure that all solder flux has been removed from the solder
joints, with alcohol, within one hour of the soldering operation.
P. Visually examine the solder joints for solder bridging, protrusions,
dewetting, insufficient or excessive solder, solder droplets, solder balls
or embedded flux.
Q. Test lamp harness using a Test Unit, (See Testing section) to assure
proper solder joint.
R. Wrap the joints and the surrounding flat conductor with a minimum of
three wraps of Mylar tape 3/8 In. wide (9.5 mm), 2 mils thick (Table
604). The wrapping must extend a minimum of one inch past the cen-
terline of the solder joints in each direction.
S. Retest the lighting system per instructions outlined in the Testing sec-
tion.
T. Reinstall lamp harness into fabric light sleeve.
Page 635
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61621
Page 636
25-66-07 13 Nov 2015
61621
1.
HEAT SHRINK EXISTING LAMP ASSEMBLY
MARK EDGE OF LAMP HOUSING HOUSING

ON FLAT CONDUCTOR, BOTH SIDES
REFLECTOR
2. LAMP (PIGTAIL SHOWN)
SOLDER (TYP)
MARKINGS
SOLDERING IRON SOLDER WICK

CONICAL TIP (SOLDER REMOVAL MATERIAL)
SOLDERING IRON REPLACEMENT LAMP ASSEMBLY

CHISEL TIP REMOVE UPPER
LAYER OF MYLAR
MARK LOCATION FOR
3. MARKINGS
MYLAR REMOVAL
EXISTING FLAT CABLE
POSITION REPLACEMENT
EXISTING
LAMP ASSEMBLY AND SOLDER
4.
TO EXISTING FLAT CONDUCTOR
DEPOSIT SOLDER VISUALLY INSPECT

SOLDER JOINTS
TAPE (3 TURNS MIN)

5.
REMOVE HEAT SHRINK COVERING

FIGURE 622
Page 637
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61621
9. Lamp Harness Replacement (Figure 623) (IPL Figure 1)
NOTE: Prior to S/N 1003A, and 1005A, 1006A.

A. Disconnect the lamp harness (30C) connectors from the power unit
(200) connectors by twisting to unlock key locks.
B. Peel away the tape and lamp mounting patches holding the lamp har-
ness (30C) around and down the slide body tubes and across the run-
way tube. Remove harness.
C. Apply cement to the new tape (yellow side) and lamp mounting patches
per the cementing instructions on Paragraph 3.A.(3) prior to installing
the new harness.
D. Position the new harness with the lamps located as shown in Figure
623.
NOTE: Use 2 In. (50.8 mm) masking tape to temporarily hold the lamp
harness in place.
E. Bond the new replacement tape in place following the cementing
instructions in Paragraph 3.A.(3).
F. Install lamp mounting patches (Table 603) as shown after removing the
masking tape.
NOTE: If stencil markings are inadvertently removed during cleaning,
replace markings using stencil ink (Table 602).
Page 638
25-66-07 13 Nov 2015
HEEL OF FLOOR
CROTCH TAPE
36 1/2 In. TYP.

(927.1 mm) CL RUNWAY TUBE
2 1/2 In. TYP.
(63.5 mm)
61621
RUNWAY TUBE
FIGURE 623
TOP SEAM C
L
25-66-07
12 1/4 In.
(311.2 mm)
LAMP HARNESS REPLACEMENT

14 In.
(355.6 mm)
14 In. TYP.
(355.6 mm)
13 Nov 2015
Page 639
61621
10. Lamp Harness Replacement (IPL Figure 1)

(S/N 1003A, 1004A through 1064A)
CAUTION: DO NOT ATTEMPT TO PULL MORE THAN ONE LAMP

AT A TIME THROUGH ANY SECTION OF WIRE GUIDE
EXCEPT ALONG RUNWAY END OF SLIDE.
A. Disconnect the lamp harness (30C) from the power unit (200) at the
connectors.
B. Inflate slide to approximately 0.25 psig (0.17 N/cm2).
NOTE: When passing a lamp through lamp position holes and toward
the next lamp position hole, gently insert a pointed tool
between the lamp and edge of cut-out and lift the edge of the
hole while pushing lamp through (Figure 624, Detail “A”).
C. Removal of existing lamp harness.
(1). Starting at the location indicated in Figure 624, push leading end
of lamp harness into runway wire guide (280) until end of lamp
harness is exposed through the lamp position holes (Figure 624,
Detail “B”).
(2). Using masking tape or scotch tape, make a loop on end of flat
wire (Figure 624, Detail “C”).
(3). Tie a 50 In. (1270 mm) length of thin cord (Table 603) to the
looped end of the lamp harness (Figure 624, Detail “C”).
(4). Gain access to the lamp harness at runway end of wire guide and
pull the lamp harness and cord completely through the runway
lane wire guide (280) until looped end is exposed from wire guide.
NOTE: Each length of cord remains in wire guide.
(5). Untie the cord from the looped end of the harness.
(6). Tie a 200 In. (5080 mm) length of thin cord (Table 603) onto the
looped end of the lamp harness (Figure 625, Detail “D”).
Page 640
25-66-07 13 Nov 2015
61621
(7). Pull lamp harness and cord completely through side lane wire
guide (300) until looped end is exposed at opposite end of side
lane wire guide.
(8). Untie cord.
(9). Repeat Paragraphs 10.C.(1) through (8) on opposite side of slide.
(10). Deflate slide.
(11). At the sill end of the slide make a loop in existing lamp harness at
blue lead wires and tape (Figure 626, Detail “F”).
(12). Tie a piece of thin cord 50 In. (1270 mm) in length to loop in blue
lead wires.
(13). Pull blue lead wires of lamp harness and cord completely through
sill end wire guide (290). Untie cord (Figure 626, Detail “F”).
(14). Repeat Paragraphs 10.C.(9) through (10) on opposite side of
slide.
(15). The cords are now in place to install the replacement lamp har-
ness.
Page 641
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61621
SILL END
DETAIL “A”
LAMP
POINTED
TOOL
DETAIL “B” WIRE

GUIDE
WIRE
GUIDE
PUSH LEADING
END OF LAMP
HARNESS
LAMP
POSITION RUNWAY
HOLE START HERE
END
DETAIL “C”
LOOPED END
50 In. NOTE: EACH LENGTH OF CORD REMAINS

(1270 mm) IN WIRE GUIDE.
CORD
TAPE FLAT WIRE

FIGURE 624
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SILL END
PULL LAMP HARNESS

AND CORD THROUGH
SIDE LANE WIRE GUIDE
DETAIL “D”
200 In.
(5080 mm)
CORD
RUNWAY END
LOOPED
END

FIGURE 625
Page 643
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Page 644
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SILL END
PULL BLUE LEAD WIRES

OF LAMP HARNESS THROUGH
SILL END WIRE GUIDE
DETAIL “F”
BLUE
TAPE LEAD
WIRES
LOOP
50 In.
(1270 mm)
CORD
RUNWAY END

FIGURE 626
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D. Lamp Harness Replacement (S/N 1003A, 1004A, 1007A through

1064A)
CAUTION: KEEP LAMP HARNESS WIRE FLAT AND FREE FROM
TWISTS.
(1). Inflate slide to approximately 0.25 psig (0.17 N/cm2).
(2). Form a loop in flat wire at the end of replacement lamp harness
and tape in place using masking or scotch tape.
(3). Form a loop in blue wire end of replacement lamp harness and
tape in place using masking or scotch tape.
(4). Starting at runway end wire guide (280) tie cord to flat wire looped
end of replacement lamp harness (Figure 627, Detail “A”).
(5). Pull cord to pull lamps into their respective lamp position holes
and cut off exposed cord, (Figure 628, Detail “B”).
(6). Tie side lane cord to the blue lead wire of the replacement lamp
harness, (Figure 629, Detail “C”).
(7). Pull lamps into their respective lamp position holes in the side
lane wire guide (300), (Figure 629, Detail “D”).
(8). Remove cord.
(9). Repeat Paragraphs 10.D.(1) through (8) on opposite side of slide.
(10). Deflate slide
(11). Tie cord at sill end wire guide (290) and pull lamp harness
through, (Figure 629, Detail “E”).
NOTE: The housing (not a lamp housing) closest to the blue leads
remains inside the wire guide.
(12). Remove cord. Remove tape and loop from wire leads.
Page 646
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DETAIL “A”
TAPE
LOOP
CORD FLAT
WIRE
BLUE
WIRE
END
REPLACEMENT
HARNESS
START HERE
LAMP
POSITION
HOLES
RUNWAY END

FIGURE 627
Page 647
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SILL END
RUNWAY
END
DETAIL “B”
PULL LAMPS INTO

LAMP POSITION HOLE
CUT OFF
EXPOSED

FIGURE 628
Page 648
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DETAIL “E”
BLUE
TAPE LEAD
WIRES
LOOP
DETAIL “D”
LAMP
POSITION
HOLE
WIRE
GUIDE
PULL LAMPS INTO

LAMP POSITION HOLES
DETAIL “C”
RUNWAY
END
SIDE
LANE CORD
BLUE
LEAD WIRE
REPLACEMENT
HARNESS

FIGURE 629
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11. Lamp Harness Replacement (IPL Figure 1) (S/N 1065A and Subs)

AT A TIME THROUGH ANY SECTION OF THE WIRE
GUIDE EXCEPT ALONG RUNWAY END OF SLIDE.
A. Disconnect the lamp harness (30C) from the power unit at the connec-
tors.
B. Inflate slide to approximately 0.25 psig (0.17 N/cm2).
C. Removal of existing lamp harness.
(1). Starting at the location indicated in Figure 629, push leading end
of lamp harness into runway end wire guide (280) until end of
lamp harness is exposed through the lamp position areas (Figure
630, Detail “B”).
(2). Using masking tape or scotch tape, make a loop on end of flat
wire (Figure 630, Detail “C”).
(3). Tie a 50 In. (1270 mm) length of thin cord (Table 603) to the
looped end of the lamp harness (Figure 630, Detail “C”).
(4). Gain access to the lamp harness at runway end of wire guide and
pull the lamp harness and cord completely through the runway
lane wire guide (280) until looped end is exposed from wire guide.
NOTE: Each length of cord remains in wire guide.
(5). Untie the cord from the looped end of the harness.
(6). Tie a 200 In. (5080 mm) length of thin cord (Table 603) onto the
looped end of the lamp harness (Figure 631, Detail “D”).
(7). Pull lamp harness and cord completely through side lane guide
(300) until looped end is exposed at opposite end of side lane
wire guide.
(8). Untie cord.
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(9). Repeat Paragraphs 11.C.(1) through (9) on opposite side of slide.

(11). At the sill end of the slide make a loop in existing lamp harness at
blue lead wires and tape (Figure 632, Detail “F”).
(12). Tie a piece of thin cord 50 In. (1270 mm) in length to loop in blue
lead wires.
(13). Pull blue lead wires of lamp harness and cord completely through
sill end wire guide (290). Untie cord, see Figure 632.
(14). Repeat Paragraphs 11.C.(12) through (14) on opposite side of
slide.
(15). The cords are now in place to install the replacement lamp har-
ness.
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SILL END
DETAIL “B”
WIRE
WIRE GUIDE
GUIDE
PUSH LEADING START HERE

END OF LAMP
HARNESS RUNWAY END
LAMP PULL LAMP HARNESS
POSITION AND CORD THROUGH
AREA WIRE GUIDE
DETAIL “C”
LOOPED END
NOTE: EACH LENGTH OF CORD REMAINS
50 In. IN WIRE GUIDE.
(1270 mm)
CORD
TAPE FLAT WIRE

FIGURE 630
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SILL END
PULL LAMP HARNESS

AND CORD THROUGH
SIDE LANE WIRE GUIDE
DETAIL “D”
WIRE
GUIDE
LOOPED
END
RUNWAY END
200 In.
(5080 mm)
CORD

FIGURE 631
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SILL END
PULL BLUE LEAD WIRES OF

LAMP HARNESS THROUGH
SILL END WIRE GUIDE
BLUE LEAD
TAPE WIRES
LOOP
50 In.
(1270 mm)
CORD
DETAIL “F”
RUNWAY END

FIGURE 632
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11. Lamp Harness Replacement (Cont’d) (IPL Figure 1)

D. Lamp Harness Installation (S/N 1065A and Subs)
CAUTION: KEEP LAMP HARNESS WIRE FLAT AND FREE FROM
TWISTS.
(1). Inflate slide to approximately 0.25 psig (0.17 N/cm2).
(2). Form a loop in flat wire at the end of replacement lamp harness
and tape in place using masking tape or scotch tape.
(3). Form a loop in blue wire end of replacement lamp harness and
tape in place using masking tape or scotch tape.
(4). Starting at runway end wire guide (280) tie cord to flat wire looped
end of replacement lamp harness. See Figure 633, Detail “A”.
(5). Pull cord to pull lamps into their respective lamp position areas
and cut off exposed cord. See Figure 633, Detail “B”.
(6). Tie side lane cord to the blue lead wire of replacement lamp har-
ness. See Figure 634, Detail “C”.
(7). Pull lamps into their respective lamp position areas in the side
lane wire guide (300). See Figure 634.
(8). Remove cord.
(9). Repeat Paragraphs 11.D.(1) through (8) on opposite side of slide.
(11). Tie cord at sill end wire guide (290) and pull lamp harness
through. See Figure 635, Detail “D”.
NOTE: The housing (not a lamp housing) closest to the blue leads
remains inside the wire guide.
(12). Remove cord. Remove tape and loop from wire guides.
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SILL END
DETAIL “A”
TAPE
LOOP
CORD FLAT
WIRE
BLUE
WIRE END
REPLACEMENT
HARNESS
START HERE
RUNWAY END
DETAIL “B”
PULL LAMPS INTO

LAMP POSITION AREAS
CUT OFF
EXPOSED
CORD

FIGURE 633
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SILL END
PULL LAMPS INTO

LAMP POSITION AREAS
IN THE SIDE LANE
WIRE GUIDE
DETAIL “C”
RUNWAY END
SIDE LANE
CORD
BLUE
LEAD WIRE
REPLACEMENT
HARNESS

FIGURE 634
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DETAIL “D”
PULL LAMP HARNESS
AND CORD THROUGH
SILL END WIRE GUIDE BLUE LEAD
TAPE WIRES
LOOP
SILL END
RUNWAY END

FIGURE 635
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12. Wire Guide Replacement (IPL Figure 1) (Figure 636)
NOTE: Wire guides (280, 290, 300) can be replaced after lamp har-
ness and lamp mounting patches are removed.
CAUTION: USE CARE NOT TO DAMAGE SLIDE WHEN REMOVING
WIRE GUIDE FROM SLIDE TUBE.
A. Using a spatula or dull blunt knife lift edge of wire guide off slide tube.
Carefully pull wire guide off slide tube.
B. Wash area with solvent. Cement new wire guide on slide per general
cementing instructions in Paragraphs 3.A.(2) through (10).
C. Dimensions for runway guides are shown below.
3 1/2 In.
(88.9 mm)
15 1/4 In.
(387.3 mm)
RUNWAY 11 7/8 In. RUNWAY
2 1/8 In.
TUBE (280.3 mm) (50.9 mm) TUBE
CL TOP SEAM CL TOP SEAM
14 In. 12 1/4 In. (311 mm)
(355.6 mm)
2 1/8 In.
(50.9 mm)
11 7/8 In.
(280.3 mm)
WIRE GUIDE REPLACEMENT

FIGURE 636
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13. Replacement of Nylon Tube on Girt Bar (Figures 637, 638, and 639)
A. Remove roll pin (81, IPL Figure 1) from one nylon stop sleeve (82, IPL
Figure 1) on the girt bar using drive punch pin (Table 603). Remove
nylon stop sleeve. Remove girt bar from girt nylon sleeve.
B. Using a round ended spatula (or equivalent) and solvent, loosen bond
between nylon sleeve and girt loop. Remove girt bar nylon tube and
clean inside of girt loop using solvent (Figure 638).
C. Roughen both ends of new nylon tube to a dull finish along a length of
approximately 3 1/2 In. (88.9 mm) using #220 grit abrasive paper
(Table 602).
NOTE: Prior to application of primer, surfaces must be cleaned using
ethyl acetate to remove oils, grease, and other contaminates.
Surfaces must be allowed to dry before priming.
D. Apply primer (Table 601) to ends of new nylon tube a distance of
approximately 3 In. (76.2 mm). Allow to dry for a minimum of two hours
(Figure 638).
E. Apply one coat of urethane cement (Table 601) to primed ends on tube.
F. Wash inside of girt bar loop with solvent for a distance of approximately
3 In. (76.2 mm) where contact will be made with nylon tube cemented
area.
G. After washed areas are dried, apply two coats of urethane cement,
allowing fifteen minutes minimum drying time between coats.
NOTE: Ensure nylon tube is centered inside girt loop.
H. When cement is dry, insert nylon tube into girt loop. Compress out-
board edges of girt inboard to expose about 3 1/2 In. (88.9 mm) of
nylon tube.
I. Apply a third coat of cement to ends of nylon tube. Immediately insert
tube into girt bar loop.
J. Smooth and press cemented areas to ensure full contact. Allow a mini-
mum of two hours cure time of bonded areas.
K. Insert girt bar through nylon sleeve. Re-install nylon stop sleeve (82,
IPL Figure 1) and roll pin (81, IPL Figure 1), see Figure 639.
Page 660
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61621
SEE DETAIL “A”
REMOVE NYLON STOP

ROLL PIN
GIRT BAR
NYLON
STOP
DETAIL “A”
GIRT BAR
LOOP GIRT BAR
NYLON SLEEVE
INSIDE GIRT BAR
LOOP
REMOVE GIRT BAR AND NYLON TUBE

FIGURE 637
Page 661
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3 1/2 In. (88.9 mm)
NYLON SLEEVE
APPLY PRIMER
(TYPICAL BOTH SIDES) 3 1/2 In. (88.9 mm)
WASH INSIDE OF GIRT

LOOP (TYPICAL
BOTH SIDES) THEN
APPLY CEMENT
3 1/2 In.
(88.9 mm)
APPROX. (BOTH SIDES)
APPLY PRIMER TO NYLON TUBE

FIGURE 638
Page 662
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GIRT BAR
NYLON SLEEVE
ROLL PIN
NYLON STOP
GIRT BAR
APPLY FINAL COAT OF CEMENT TO NYLON TUBE

FIGURE 639
Page 663
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14. Girt Bar Replacement
A. Replace girt bar only by removing the roll pin (81, IPL Figure 1) from
one nylon stop sleeve (82, IPL Figure 1) using drive punch pin (Table
603). Remove 1 In. (25.4 mm) nylon stop sleeve (Figure 640).
NOTE: Save roll pin after removing from nylon sleeve for installation of
new girt bar.
B. Slide girt bar from nylon sleeve which is bonded into the girt assembly.
C. Remove roll pin from one nylon stop sleeve on new girt bar using drive
punch pin (Table 603). Remove 1 In. (25.4 mm) nylon stop sleeve and
18 In. (457.2 mm) long nylon sleeve.
D. Insert new bar through girt loop. Re-install nylon stop sleeve (82, IPL
Figure 1) and insert roll pin (81, IPL Figure 1), (Figure 641).
Page 664
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GIRT ASSEMBLY
SEE DETAIL “A”
REMOVE EXISTING
GIRT BAR
REMOVE NYLON SLEEVE
GIRT BAR
DETAIL “A”
REMOVE ROLL PIN
REMOVE GIRT BAR

FIGURE 640
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SEE DETAIL “B”
INSTALL GIRT BAR
DETAIL “B”
INSTALL ROLL PIN
GIRT BAR
INSTALL NYLON SLEEVE
INSTALL GIRT BAR

FIGURE 641
Page 666
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TABLE OF CONTENTS
ASSEMBLY
Page
1. Assembly Materials/Equipment 702
2. Preparatory Safety Instructions 703
3. Relief Valve Installation (B18254-5) (Pre S.B. 737 103-25-31) 704
4. Relief Valve Installation (64154-5) (Post S.B. 737 103-25-31) 705
5. Pressure Test Valve Installation 706
6. Aspirator Installation 707
7. Re-Entry Webbing Attachment 711
8. Folding Procedure 712
9. Storage Instructions 712
Page 701
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61621
1. Assembly Materials/Equipment (Table 701)

with the following symbol

Talc or Powdered As Commercially Prevents joining of
Soapstone Required Available areas of exposed
cement, reflective coat-
ing compound, or sten-
cil ink.
Thread and Detent As McGee Threaded fitting lubri-
Lubricant Required Industries, Inc. cant.
McLube 1190 V04672
Tape, Green  As Commercially Provides chafe protec-
1.0 In. (25.4 mm) wide Required Available tion from metal fittings.
PPP-T-60-1
Tape, Black Fire Retardant As Air Cruisers Provides chafe protec-
1.0 In. (25.4 mm) wide Required V70167 tion from metal fittings.
M12397-1
(Reference S.I.L. 25-252)
Dow Corning Molykote As Dow Corning Gasket/washer lubri-
or equivalent to Required Corporation cant.
MIL-G-4343 V5D028 or
Commercially
Available
6914V-SD Inc. core from pressure test
TO2298 V70167 valve.
(Pre S.B. 737 103-25-31)
ASSEMBLY MATERIALS/EQUIPMENT
Page 702
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61621

Tool - Removal/Installation, 1 Mirada Installs/removes inflate/
and Handle Research & deflate and relief
B51025 and A51280 Mfg. Co. valves.
(Post S.B. 737 103-25-31) V08407
ASSEMBLY MATERIALS/EQUIPMENT
2. Preparatory Safety Instructions

Page 703
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61621
3. Relief Valve Installation (B18254-5) (Figure 701) (IPL Figure 1)

(Pre S.B. 737 103-25-31)
CAUTION: DO NOT EXCEED MAXIMUM TORQUE LIMIT SPECI-

FIED IN TABLE 801.
A. Apply a medium coat of Dow Corning Molykote lubricant (Table 701) to
the rubber gasket. Install rubber gasket in valve inside diameter coun-
terbore. Ensure washer is properly seated.
CAUTION: MAKE SURE NO LUBRICANT ENTERS THE INSIDE OF
THE RELIEF VALVE.
B. Prior to installation, apply a medium coating of McLube 1190 (Table
701) to the relief valve threads.
C. Install relief valve (220) into flange and tighten per Table 801 using
relief valve tool (Table 702) and torque wrench.
RELIEF VALVE
THREADS
GASKET
SLIDE FABRIC
FLANGE
RELIEF VALVE INSTALLATION

(P/N B18254-5)
FIGURE 701
Page 704
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4. Relief Valve Installation (64154-5) (Figure 702) (IPL Figure 1)

(Post S.B. 737 103-25-31)
CAUTION: DO NOT EXCEED MAXIMUM TORQUE LIMIT SPECI-

FIED IN TABLE 801.
A. Prior to installation apply a medium coating of Dow Corning Molykote
(Table 701) to the sealing gasket.
B. Using removal/installation tool (Table 701) screw relief valve and install
into flange. Torque per Table 801.
RELIEF VALVE HANDLE

TOOL
RELIEF VALVE
FLANGE
GASKET
RELIEF VALVE INSTALLATION

(P/N 64154-5)
FIGURE 702
Page 705
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61621
5. Pressure Test Valve Installation (Figure 703) (IPL Figure 1)
NOTE: Pressure test valve located on the aspirator (230) inlet fitting.
A. Install the pressure test valve core (242) into the valve stem using the
valve core tool (Table 702).
B. Engage shoulder of pressure test valve core and hand tighten.
C. Install cap.
D. Install tube (245) over cap and valve stem.
ASPIRATOR
VALVE STEM
VALVE CORE
TOOL
VALVE CORE
CAP
PRESSURE TEST VALVE ASSEMBLY

FIGURE 703
Page 706
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6. Aspirator Installation (Figure 704) (IPL Figure 1)
CAUTION: DO NOT DAMAGE ASPIRATOR RUBBER MOUNTING

FLANGE SEALING SURFACE.
NOTE: Pour approximately two tablespoons of talc or powered soap-
stone (Table 701) into mounting blister opening before install-
ing aspirator.
A. Insert aspirator (230) into mounting blister.
B. Engage mounting lip on aspirator into annular groove of mounting
flange.
MOUNTING
BLISTER
MOUNTING FLANGE
MOUNTING LIP
ANNULAR GROOVE
ASPIRATOR
ASPIRATOR INSTALLATION
FIGURE 704
Page 707
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61621
6. Aspirator Installation (Cont’d) (Figure 705) (IPL Figure 1)

C. Position the aspirator (230) in the rubber mounting flange so that the
inlet fitting is in line with the alignment mark on the rubber mounting
flange blister.
MOUNTING BLISTER
ASPIRATOR
ALIGNMENT MARK
INLET FITTING
FIGURE 705
Page 708
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61621

D. Install worm drive clamp (230) in the annular groove in the mounting
flange.
E. Center the clamp screw under centerline of the inlet fitting.
F. Tighten clamp screw (Table 801).
MOUNTING
BLISTER
WORM DRIVE CLAMP
ASPIRATOR
CLAMP SCREW
INLET FITTING
INLET FITTING
MOUNTING
LIP
ANNULAR
GROOVE CLAMP SCREW
FIGURE 706
Page 709
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61621

G. Apply three layers of green tape (Table 701) over clamp screw housing
of band. Tape should extend 1 In. (25.4 mm) on both sides of housing.
H. Wrap the worm drive clamp (210) with three layers of 1 In. (25.4 mm)
black tape (Table 701).
THREE LAYERS OF
INLET FITTING
GREEN TAPE
CLAMP SCREW
HOUSING
WORM DRIVE
EXTEND 1 In. (25.4) CLAMP
BOTH SIDES
THREE LAYERS OF
BLACK TAPE
FIGURE 707
Page 710
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61621
7. Re-Entry Webbing Attachment (Figure 708)
A. Fasten the re-entry webbing to the slide by joining the mating Velcro
fasteners.
RE-ENTRY
WEBBING
VELCRO
FASTENERS
RE-ENTRY WEBBING ATTACHMENT

FIGURE 708
Page 711
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61621
8. Folding Procedure
A. For Folding Procedure see Appendix-1.
9. Storage Instructions
A. Store the evacuation slide assembly in a cool, dry location in original

shipping container. Store separate components in clean protective con-
tainers. It is desirable to store the evacuation slide assembly packed in
its container at a temperature of 75° ± 15°F (23.9°C ± 8.3°C). Maxi-
mum permissible storage conditions for extended periods must not
exceed -40°F to + 160°F (-40°C to + 71.1°C).
NOTE: Storage outside of allowable conditions may activate pressure
relief devices (Frangible Discs and/or Fusible Plugs if so
equipped).
B. A periodic check of reservoir pressure is recommended, particularly
when equipment is subject to extremes of permissible storage condi-
tions.
WARNING: RESERVOIRS ARE FULLY CHARGED. HANDLE WITH
CARE TO PROTECT PERSONNEL FROM POSSIBLE
INJURY.
C. During storage, the evacuation slide should be handled with extreme
care so as not to chafe, cut, or otherwise damage the fabric surfaces or
the valise.
D. For shipment, pack the folded slide and valise assembly in the original
shipping container or equivalent in accordance with best commercial
shipping practices. Observe all Department of Transportation (DOT,
U.S.A.) regulations for shipment of charged gas reservoirs.
Page 712
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61621
TABLE OF CONTENTS
FITS AND CLEARANCES
Page
1. Torque Wrench Instructions 802
2. Torque Limits 803
Page 801
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61621
1. Torque Wrench Instructions
CAUTION: DO NOT EXCEED TORQUE VALUE NOTED. IF MAXI-

MUM TORQUE IS EXCEEDED, THREAD COULD BE
DAMAGED AND/OR SEALING SURFACES DISTORTED.
A. Torque wrenches must be calibrated at frequent intervals using weights
and a measured lever arm to preclude inaccuracies due to mishandling
or considerable usage. Do not check one wrench against another.
Page 802
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61621
2. Torque Limits
TORQUE
NOMENCLATURE TORQUE MAXIMUM
MINIMUM
Worm Drive Clamp Screws 28 In. Lb. 32 In. Lb.

2.3 Ft. Lb. 2.7 Ft. Lb.
(3.2 N-m) (3.6 N-m)
Relief Valve (B18254-5) and 10 In. Lb. 12 In. Lb.
Relief Valve Test Plug .83 Ft. Lb. 1.0 Ft. Lb.
(1.1 N-m) (1.3 N-m)
Relief Valve (64154-5) 25 In. Lb. 30 In. Lb.
2.1 Ft. Lb. 2.5 Ft. Lb.
(2.8 N-m) (3.4 N-m)
Cable Guide Tube to Cable Guide 40 In. Lb. 50 In. Lb.
Port 3.3 Ft. Lb. 4.2 Ft. Lb.
(4.5 N-m) (5.6 N-m)
Hose Assembly to Aspirator 230 In. Lb. 250 In. Lb.
19.2 Ft. Lb. 20.8 Ft. Lb.
(25.8 N-m) (28.0 N-m)
Hose to Inflation Valve 260 In. Lb. 280 In. Lb.
21.7 Ft. Lb. 23.3 Ft. Lb.
(29.4 N-m) (31.6 N-m)
Pressure Test Valve Body/Base 2 1/2 turns beyond hand tight.
to Aspirator Inlet Fitting
TABLE OF TORQUE LIMITS
TABLE 801
Page 803, 13 Nov 2015

25-66-07 Page 804, Blank
61621
TABLE OF CONTENTS
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
Page
2. Special Tools, Fixtures, and Equipment. 902
3. Special Tools, Fixtures, and Equipment Illustrated 907
Page 901
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61621
A. The tools, fixtures and equipment listed in Table 901 and shown in Fig-
ures 901 through 906 are recommended for use during Testing, Disas-
sembly, Cleaning, Repair, and Assembly.
2. Special Tools, Fixtures, and Equipment (Table 901)

with the following symbol .

Test Set (Light System) 1 D.M.E. Corp. Verifies power unit volt-
Model TU-12 or TU-14 V55827 age and lamp harness
amperage.
(Testing)
Test Set (Light System) 1 BaseWest, Inc. Verifies power unit volt-
Model TS-420 V0MF00 age and lamp harness
(Alternative to TU-14) amperage.
(Testing)
Thermometer 1 Commercially Measures ambient
[Scale increments not more Available temperature. (Testing)
than 1°F (0.6 °C)] 
Stopwatch, Plain Timer 1 Commercially Measures inflation
(1/10 Seconds Gradua- Available time of system during
tions)  functional deployment
test. (Testing)
Barometer 1 Commercially Measures ambient
[Scale increments not more Available pressure. (Testing)
than 0.1 In. (2.5 mm)] 

Page 902
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61621

Hand Roller/Castor Wheel 1 Everhard Distributes pressure along
MR02040 Products, Inc. bonded fabric repairs.
(2 In. (50.8 mm) dia. x V72274 (Repair)
2 In. (50.8 mm) wide with
handle) 
Tool - Valve Core 1 Rus Indus- Installs/removes valve
6914V-SD tries Inc. core from pressure test
(Testing, Disassembly,
Assembly)
Tool - Adapter, Pressure 1 Air Cruisers Connects manometer/
Test Valve V70167 pressure gage to pressure
C37099-103 test valve for inflatable
assembly pressure read-
ing. (Testing)
Manometer (water) 1 Commercially Measures pressure of
0 to 5.0 psig Available inflatable assembly.
(0 to 3.4 N/cm2) *  (Testing)
Manometer (Meriam Fluid) 1 Commercially Measures pressure of
0.5 to 5.0 psig Available inflatable assembly.
(0.3 to 3.4 N/cm2) (Testing)
[9.4 In. (238.8 mm) M. F.
per 1.0 psig (0.7 N/cm2)] * 
Pressure Gage 1 Commercially Measures pressure of
(Mechanical/Digital) Available inflatable assembly.
Scale Range 0 to 15 psig (Testing)
(0 to 10.3 N/cm2) * 
2.0% Accuracy
*Alternatives

Page 903
25-66-07 13 Nov 2015
61621

Safety Plug 1 Commercially Seals valve outlet port to
(Valve Outlet Port) Available prohibit leakage, dam-
AN814-10 or AS5169-10 age, and contamination.
(Assembly, Disassembly)
Spatula (Pusher) 1 Air Cruisers Evenly distributes, and
PA-1  V70167 removes wrinkles from,
bonded fabric repairs.
(Repair)
Test-Plug 1 Air Cruisers Replaces relief valve; pro-
C19851-101 V70167 hibits inflatable assembly
(Pre S.B. 737 103-25-31) pressure loss during over-
pressure testing. (Testing)
TO2298 V70167 valve. (Testing, Disassem-
(Pre S.B. 737 103-25-31) bly, Assembly)
Tool - Installation/Removal, 1 Mirada Installs/removes inflate/
and Handle Research & deflate and relief valves.
B51025 and A51280 Mfg. Co. (Testing, Disassembly,
(Post S.B. 737 103-25-31) V08407 Assembly)
Relief Valve Test Clamp 1 Air Cruisers Retains relief valve in
TO5862 V70167 “closed” position; prohib-
(Post S.B. 737 103-25-31) its inflatable assembly
pressure loss during over-
pressure or leakage test-
ing. (Testing)
Hydrostatic Test Machine 1 Air Cruisers Overpressure tests hose
TO4853  V70167 assemblies. (Testing)
Magnifier, Eye Loupe 1 Commercially Used for precise examina-
10X power  Available tion of lamp housing.
(Repair)

Page 904
25-66-07 13 Nov 2015
61621

Soldering Iron 600°-800° F 1 Commercially Heats solder for appli-
(315.6° -426.7°C) Available cation. (Repair)
Heat Range
Soldering Iron Tip 1 Commercially Melts mylar insulation.
Screwdriver or Chisel Tip Available (Repair)
Soldering Iron Tip 1 Commercially Applies solder. (Repair)
Conical or Pencil Tip Available
Desoldering Bulb  1 Commercially Removes solder.
Vacuum Action, Teflon Tip Available (Repair)
Shield, Wood  1 Commercially Protects fabric from sol-
1/4 x 12 x 12 In. Available dering iron. (Repair)
(6.4 x 304.8 x 304.8 mm)
(Approximate dimensions)
Bottle, Dispensing, with 1 Commercially Solvent/solution dis-
spout or pump  Available penser. (Repair)
Vacuum, Industrial Type 1 Gast Mfg. Removes air from inflat-
Model R2103 VZY311 or able sub-assembly.
25-26 In. Air Cruisers (Folding Procedure)
(62-65 mb) H2O V70167
Adapter, Vacuum 1 Air Cruisers Adapts vacuum to aspi-
D14105-101 V70167 rator/jet pump to
remove air from inflat-
able sub-assembly.
(Folding Procedure)
Cloth Clamp 2 Singer Indus- Holds fabric folds in
3539 trial Sewing place during folding
Products procedure. (Folding
Cutters Procedure)
Exchange Div.
V1CHP3

Page 905
25-66-07 13 Nov 2015
61621

Protective Blanket 1 Commercially Personnel safety equip-
Furniture Moving Type Available ment used during over-
(Quilted polyester fabric pressure testing.
with cotton stuffing) (Testing)
Minimum Approximate size
80 x 72 In.(2032 x 1829
mm) and weight
6.25 Lb. (2.8 kg) 

Page 906
25-66-07 13 Nov 2015
61621
3. Special Tools, Fixtures, and Equipment Illustrated
MANOMETER
PRESSURE TEST
VALVE ADAPTER
(C37099-103)
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT ILLUSTRATED

FIGURE 901
Page 907
25-66-07 13 Nov 2015
61621
VALVE CORE
TOOL (6914V-SD)
RELIEF VALVE
PLUG (C19851-101)
SPATULA/PUSHER
(PA-1)
HAND ROLLER
(MR02040)

FIGURE 902
Page 908
25-66-07 13 Nov 2015
61621
RELIEF VALVE
TEST CLAMP
(TO5862)
RELIEF VALVE
TOOL (T02298)
TOOL
(B51025)
HANDLE
(A51280)

FIGURE 903
Page 909
25-66-07 13 Nov 2015
61621
VACUUM ADAPTER
(D14105-101)
CLOTH CLAMP
(3539)
SPECIAL TOOLS, FIXTURES AND EQUIPMENT ILLUSTRATED

FIGURE 904
Page 910
25-66-07 13 Nov 2015
61621
VOLTMETER TEST CONNECTORS

PUSH TO TEST
POWER UNIT POWER UNIT
TEST
ONLY

LAMP AND
HARNESS LAMP TEST
PUSH TO TEST TS-10

TS-10 PROCEDURE
AMMETER D PROCEDURE ONLY
C
E
OFF ARM
MODEL TU-12
B F TEST UNIT
A
LOAD SELECTOR ACTIVATE
TEST UNIT MODEL TU-12
WARNING SHOCK HAZARD

SERVICING UNIT CORPORATION
FORT LAUDERDALE
J4 FLORIDA
J-1 E-1 E-2 J-3

115 VAC
TEST SET NEEDS
FUSE CHARGE
1 AMP
CHARGING
C D
LOW
S-6
B
E VOLTMETER AMMETER
VOLTS AMPS ON
A F S-5 S-2 S-4 S-3 S-1

BATTERY TEST TEST
TEST SET MODEL TU-14
SPECIAL TOOLS, FIXTURES AND EQUIPMENT ILLUSTRATED

FIGURE 905
Page 911
25-66-07 13 Nov 2015
61621
TS-420 TEST SET
SELF TEST LOW BATT

(5VDC POWER SUPPLY) (INTERNAL BATTERY)
BASEWEST
TS-420 TEST SET
Escape Slide Lighting Systems
Digital Voltmeter/Ammeter
with 5VDC Power Supply
VOLTMETER
C D
B
A E
NO F
LOAD
AMMETER PRESS TO TEST LOAD SELECTOR

FIGURE 906
Page 912
25-66-07 13 Nov 2015
61621
HYDROSTATIC
TEST MACHINE
(TO4853)

FIGURE 907
Page 913, 13 Nov 2015

25-66-07 Page 914, Blank
61621
TABLE OF CONTENTS
ILLUSTRATED PARTS LIST
Page
1. General 1002
2. Material Arrangement 1002
3. How to Use the Parts List 1005
4. List of Abbreviations/Symbols/Terms/Definitions 1006
5. Vendor Codes 1008
6. Numerical Index 1008
7. Detailed Parts List 1008
Page 1001
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61621
1. General
This illustrated parts list (IPL) contains the complete listing of all
replaceable parts of the inflation system.
2. Material Arrangement
This IPL is comprised of the following sections.

A. Introduction
The introduction contains all the information necessary for the use of
this IPL. It also contains a list of abbreviations used in the detailed
parts list, and a list of manufacturer codes, names, and addresses.
B. Numerical Index
This section has a list of all part numbers in the detailed parts list in
alpha-numerical sequence with cross-reference to the IPL Fig./Item
numbers as well as the quantity.
Sequence as follows:
(1). Letters A through Z (“O” to be considered zero).
(2). Numerals 0 through 9.
C. Detailed Parts List
The detailed parts list illustrates all parts attached by means other than
riveting, sewing, or cementing. Parts attached by these means are
included when the next higher assembly is replaced.
(1). Column FIG/ITEM
The first number in the first line of a page indicates the number of
the first figure illustrating the part. The second number indicates
the item number by which the part is identifiable on the illustra-
tion. A dash (-) placed before the item number indicates that the
part is not illustrated.
Page 1002
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61621
(2). Column PART NUMBER

The part number column contains the original manufacturer part
number. When standard parts are used, the standard part num-
ber is listed in this column.
(3). Column AIRLINE PART NUMBER
This column is left blank for airline use.
(4). Column NOMENCLATURE
(a). Indenture System
The indenture system shows the relationship of parts and
assemblies to next higher assemblies or installations, as fol-
lows:
1234567
Assembly or installation assembly (RF) number
Attaching parts for assembly or installation
.Detail parts for assembly

Sub-assembly
Attaching parts for sub-assembly
..Detailed parts for sub-assembly

Sub-sub-assembly
Attaching parts for sub-sub-assembly
...Detailed parts for sub-sub-assembly

(b). Attaching Parts
Attaching parts are captioned ATTACHING PARTS and are
listed immediately following the parts attached. The *** symbol
follows the last item of the attaching parts group.
Page 1003
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61621
(c). Vendor Code

Parts manufactured by companies other than Air Cruisers are
identified by an appropriate vendor code following the nomen-
clature. Vendor codes are in accordance with current issues of
Federal Supply Codes for Manufacturers Catalog handbooks
H4-1, H4-2, and H4-3, and are preceded by the letter “V”.
Standard parts such as AN, MS, etc. are not identified by ven-
dor code.
(5). Column EFF CODE
The Effectivity Code Column establishes part relationships with
units or assemblies which are essentially the same but have
minor deviations. These units or assemblies are assigned refer-
ence letters such as A, B, C, etc. Parts which are not common to
all configurations but are associated with one or more of the
coded lead items carry the letter or letters assigned to the lead
item with which it is associated. Where a part is common to all
lead items, the effectivity column is left blank.
(6). Column UNITS PER ASSEMBLY
This column contains the quantity of a specific catalog sequence
numbered part required in the build sequence of only one (where
more than one exists), next higher sub-sub-assembly, sub-
assembly, assembly or installation level as applicable. For bulk
items, the letters “AR” are inserted in the quantity column to indi-
cate “as required”. Where items are listed for reference purposes,
“RF” is inserted.
Page 1004
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61621
3. How to Use the Parts List
A. If the part number is known

(1). Find the part number in the Numerical Index. Note the Figure and
item number.
(2). Turn to the Figure.
(3). Locate the part on the illustration and in the parts list by item
number.
B. The part number is unknown
(1). Refer to the applicable Figure and look for the illustration of the
part.
(2). Note the item number.
(3). Turn to the applicable parts list and refer to the corresponding
item number.
Page 1005
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61621
4. List of Abbreviations/Symbols/Terms/Definitions
A. Abbreviations/Symbols
The following abbreviations/symbols are the more commonly used in
this IPL. This list is to be used in conjunction with the Glossary of
Abbreviations and Symbols, Introduction section.
AR As Required NO. Number

ASSY. Assembly NP Not Procurable
BKDN Breakdown R Revised
CMM Component RF. Reference
Maintenance Manual
EFF. Effectivity R.H. Right Hand
FIG. Figure R.S. Right Side
IPL Illustrated Parts List SUBS Subsequent
L.H. Left Hand *** End of Attaching Hardware
L.S. Left Side - Item Not Illustrated
NHA Next Higher Assembly  Denotes Intentionally Left
Blank
Page 1006
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61621
B. Interchangeability Terms, Abbreviations, and Definitions
TERM ABBREVIATION DEFINITION
Superseded SUPSD BY The part is superseded by and is one-way inter-

by changeable with the item number shown (old
part number can be used as replacement only
where old part number was installed).
Supersedes SUPSDS The part supersedes and is one-way inter-
changeable with the item number shown (new
part number is acceptable replacement for old or
new part number).
Service SB PRE Identifies when a service bulletin (SB) has an
Bulletins SB POST effect on a part. PRE shows the condition of the
part before the work in the service bulletin is
done; POST shows the condition after the work
is done.
Alternate ALT The part agrees with all functional and structural
specifications, but the external dimensions, con-
nection installation, and/or mounting provisions
are different. Rework or possible changes can
be necessary.
Replaced by REPLD The part is replaced and is two-way interchange-
able with the item number shown (old part num-
ber can replace either old or new part number
when removed).
Replaces REPLS The part replaces and is two-way interchange-
able with the item number shown (new part num-
ber is acceptable replacement for old or new
part number).
Page 1007
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61621
5. Vendor Codes
Table 1001 lists data for manufactures whose code appears in the
Nomenclature Column of the Detailed Parts List. Absence of a vendor
code following a part number in the detailed parts list identifies an Air
Cruisers part.
CODE NAME/ADDRESS
V70167 Air Cruisers
1747 State Route 34
Wall, NJ 07727-3935 USA
V81205 The Boeing Company
7755 E Marginal Way S
Seattle, WA 98108-4002 USA
V55827 D. M. E. Corporation
6830 N. W. 16th Terrace
Fort Lauderdale, FL 33309-1518 USA
V8S111 Rus Industries, Inc.
3255 Lockport Rd.
Niagra Falls, NY 14305-2309 USA
V0MF00 BaseWest, Inc.
4240 116th Ter. N.
Clearwater, FL 33762-4971 USA
V3CKH7 Federal Process Corp.
4520 Richmond Rd.
Cleveland, OH 44128-5982 USA
V08407 Mirada Research & Manufacturing Inc.
809 4th St.
Ironton, MN 56455-2161 USA
V79833 Clifton Adhesive, Inc.
48 Burgess Place
Wayne, NJ 07470-6734 USA
VENDOR INFORMATION
Page 1008
25-66-07 13 Nov 2015
61621
CODE NAME/ADDRESS
V04672 McGee Industries, Inc., McLube
9 Crozerville Rd.
Aston, PA 19014-1431 USA
VZY311 Gast Manufacturing
82 Reserve Rd.
Artarmon, NSW 2064 Australia
V1CHP3 Singer Industrial Sewing
Products
Cutters Exchange Div.
1224 Heil Quaker Blvd.
P.O. Box 7017
LaVergne TN 37086-3515 USA
VENDOR INFORMATION
Page 1009
25-66-07 13 Nov 2015
61621
6. Numerical Index
A. Numerical index listed on pages 1011 through pages 1013.
7. Detailed Parts List
A. Detailed parts listed on pages 1015 through 1023.
Page 1010
25-66-07 13 Nov 2015
61621
AIRLINE IPL TOTAL

PART NUMBER ITEM
PART NUMBER FIGURE REQUIRED
A3-06-0672-107 1 20 1
A3-06-0672-108 1 30 1
B14056-008 1 330 1
1 340 1
B14056-910 1 110 1
B16045-1 1 210 1
B18254-5 1 220 1
SUPSD BY 64154-5
C17734-103 1 40 1
SUPSD BY 63494-1
C19347-119 1 160 1
C19928-109 1 190
DELETED
C19928-109 1 320 1
SUPSD BY 63007-105
C31062-3 1 50 1
C31509-101 1 140 1
C31713-105 1 70 1
D17992-109 1 170 1
M11606-4 1 93 1
1 94 1
1 95 1
MS28777-10 1 100 1
MS51923-599 1 81 2
P4-01-0033-210 1 200 1
12B11347-0 1 242 1
14C13060-0 1 91 1
15A17168-1 1 245 1
26B17522-3 1 60 1
60493-101 1 230 1
61621-469 1 1 RF
61690-469 1 10 1
61694-101 1 92 1
61695-101 1 90 1
61706-101 1 150 1
61744-103 1 130A 1
SUPSDS 61814-1
61752-101 1 120 1
Page 1011
25-66-07 13 Nov 2015
61621
AIRLINE IPL TOTAL

PART NUMBER ITEM
61768-101 1 180 1
SUPSD BY 61768-201
61768-201 1 180A 1
SUPSDS 61768-101
61809-101 1 260 1
SUPSD BY 63097-101
61812-1 1 270 1
61813-101 1 250 1
61814-1 1 130 2
SUPSD BY 61744-103
61823-101 1 215 1
62376-107 1 20A 1
SUPSD BY 62929-103
62376-108 1 30A 1
SUPSD BY 62929-104
62929-103 1 20B 1
SUPSD BY A3-06-0672-108
62929-104 1 30B 1
SUPSD BY 62929-107
62929-107 1 30C 2
SUPSDS 62929-103, -104
63007-105 1 190A
DELETED
63007-105 1 320A 1
SUPSDS C19928-109
63097-101 1 260A 1
SUPSDS 61809-101
63409-101 1 280 2
63410-101 1 290 2
63412-101 1 300 2
63494-1 1 40A 1
SUPSDS C17734-103
SUPSD BY67744-1
64154-5 1 220A 1
SUPSDS B18254-5
64172-1 1 310 1
65216-101 1 240A 1
SUPSDS 9166L5
Page 1012
25-66-07 13 Nov 2015
61621
AIRLINE IPL TOTAL

PART NUMBER ITEM
65217-1 1 241 1
65217-3 1 243 1
65C26196-6 1 80 1
66-157556-6 1 85 1
67744-1 1 40B 1
SUPSDS 63494-1
69-56382-6 1 82 2
9166L5 1 240 1
SUPSD BY 65216-101
Page 1013
25-66-07 13 Nov 2015
61621
Page 1014
25-66-07 13 Nov 2015
61621
1 130A
80
10
70 150
90
93
260A
94 91
95
250
92
270
170

IPL FIGURE 1
(SHEET 1 OF 4)
Page 1015
25-66-07 13 Nov 2015
61621
260A
40A, 40B
180, 180A
40 110
100
140
60
50
310
200
320, 320A
120

IPL FIGURE 1
(SHEET 2 OF 4)
Page 1016
25-66-07 13 Nov 2015
61621
210
160
230
240A, 242
290 245
290
30C
30C
300
300
280

IPL FIGURE 1
(SHEET 3 OF 4)
Page 1017
25-66-07 13 Nov 2015
61621
220A
220A
(POST S.B. 737 103-25-31)
220
220
(PRE S.B. 737 103-25-31)

IPL FIGURE 1
(SHEET 4 OF 4)
Page 1018
25-66-07 13 Nov 2015
61621
UNITS
FIG. AIRLINE NOMENCLATURE EFF.
PART NUMBER PER
ITEM PART NO. 1234567 CODE
ASSY.
1
1 61621-469 Evacuation Slide A RF
Assembly
10 61690-469 .Slide Assembly 1
R -20 D19860-107 ..Harness, Lamp 1
(A3-06-0672-107; V55827)
(Supsd by Item 20A)
-20A 62376-107 ..Harness, Lamp 1
(Supsds Item 20)
(Supsd by Item 20B)
-20B 62929-103 ..Harness, Lamp 1
(Supsds Item 20A)
(Supsd by Item 30C)
R -30 D19860-108 ..Harness, Lamp 1
(A3-06-0672-108; V55827)
(Supsd by Item 30A)
-30A 62376-108 ..Harness, Lamp 1
(Supsds Item 30)
(Supsd by Item 30B)
-30B 62929-104 ..Harness, Lamp 1
(Supsds Item 30A)
(Supsd by Item 30C)
30C 62929-107 ..Harness, Lamp 2
(Supsds Items 20B, 30B)
40 C17734-103 .Hose Assembly 1
(Supsd by Item 40A)
- Item Not Illustrated
Page 1019
25-66-07 13 Nov 2015
61621
UNITS
PART NUMBER PER
ASSY.
1
40A 63494-1 .Hose Assembly 1
(Supsds Item 40)
(Supsd by Item 40B)
40B 67744-1 .Hose Assembly 1
(Supsds Item 40A)
50 C31062-3 .Tube, Cable Guide 1
60 26B17522-3 .Cable Guide Nut 1
70 C31713-105 .Girt Release Cable 1
Assembly
80 65C26196-6 .Girt Bar Assembly 1
(Short)
-81 MS51923-599 ..Pin, Roll 2
-82 69-56382-6 ..Stop, Nylon (V81205) 2
-85 66-15755-6 ..Sleeve (V81205) 1
90 61695-101 .Mooring Line Assembly 1
91 14C13060-0 ..Release, Manual 1
92 61694-101 ..Release, Automatic 1
93 M11606-4 ..Cord, Olive Drab 1
27 In. Long (685.8 mm)
179 In. Long (454.6 mm)
67 In. Long (1701.8 mm)
100 MS28777-10 .Back-Up Ring 1
(Used with Item 40 Only)
Page 1020
25-66-07 13 Nov 2015
61621
UNITS
PART NUMBER PER
ASSY.
1
110 B14056-910 .O-Ring 1
120 61752-101 .Valise Assembly (Auto) 1
-130 61814-1 .Inspection Log 2
(Supsd by Item 130A)
130A 61744-103 .Maintenance Release 1
Record (Supsds Item 130)
140 C31509-101 .Chafing Cover 1
150 61706-101 .Girt, Detachable 1
160 C19347-119 .Frangible Link 1
170 D17992-109 .Pull Handle Assembly 1
180 61768-101 .Reservoir and Valve 1
Assembly
(DOT-E-11194-3295)
(See CMM 25-65-20 for
BKDN)
180A 61768-201 .Reservoir and Valve 1
Assembly
(DOT-E-11194-3295)
(See CMM 25-65-20 for
BKDN)
(Supsds Item 180)
R -190 C19928-109 Deleted
R -190A 63007-105 Deleted
200 D19859-103 .Power Unit 1
(P4-01-0033-210; V55827)
Page 1021
25-66-07 13 Nov 2015
61621
UNITS
PART NUMBER PER
ASSY.
1
210 B16045-1 .Clamp Assembly 1
R -215 61823-101 ..Tube Assembly (NP) 1
R 220 B18254-5 ...Relief Valve 1
(Pre S.B. 737 103-25-31)
R 220A 64154-5 ...Relief Valve 1
(Supsds Item 220)
(Post S.B. 737 103-25-31)
230 60493-101 .Aspirator Assembly 1
-240 9166L5 ..Pressure Test Valve 1
w/Cap (V27783)
240A 65216-101 ..Valve and Cap Assy 1
(Supsds Item 240)
-241 65217-1 ...Valve 1
242 12B11347-0 ...Core, Valve 1
-243 65217-3 ...Cap 1
245 15A17168-1 ..Tube 1
250 61813-101 .Body, Disconnect 1
Assembly
-260 61809-101 .Protector, Gage 1
260A 63097-101 .Protector, Gage 1
(Supsds Item 260 as a
Product Improvement)
Page 1022
25-66-07 13 Nov 2015
61621
UNITS
PART NUMBER PER
ASSY.
1
270 61812-1 .Sleeve, Disconnect 1
***
280 63409-101 ..Guide, Wire, Runway 2
290 63410-101 ..Guide, Wire, Sill End 2
300 63412-101 ..Guide, Wire, Side Lane 2
310 64172-1 .Gage Positioner 1
(Post S.B. 103-25-28)
R 320 C19928-109 .Lanyard, Light Activating 1
R 320A 63007-105 .Lanyard, Light Activating 1
(Supsds Item 320)
R -330 B14056-008 ..O-Ring 1
(Used with Item 320)
R -340 B14056-008 ..O-Ring 1
(Used with Item 320A)
Page 1023, 13 Nov 2015

25-66-07 Page 1024, Blank
61621
FOLDING PROCEDURE APPENDICES
FOLDING
APPENDIX EVACUATION SLIDE
PROCEDURE
Appendix-1 61621-469 P-11990
APPX-1
25-66-07 13 Nov 2015

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To: Holders of 737-300/400/500 Aircraft Slide Evacuation System

(P/N 61621-469, manufactured by Air Cruisers) Component Maintenance

Revision No. 12, Dated 13 Nov 2015

Revision No. 12 of Component Maintenance Manual 25-66-07 reflects pages

ACC P/N 61621-469

COMPONENT MAINTENANCE MANUAL

ORIGINAL ISSUE: 22 JULY 1991

RETAIN THIS RECORD IN THE FRONT OF THE MANUAL. UPON

REVISION REVISION ENGINEER WRITERS DATE

TEMPORARY REVISION RECORD

DATE INSERTED REMOVED

TR25-1 9 Feb 1994 16 Dec 1996

SERVICE BULLETIN RECORD

SERVICE BULLETIN / DATE

103-25-28 4 Dec 1998 13 Apr 2012 Optional Installation of Gage Posi-

737 103-25-38 11 Oct 2002 13 Apr 2012 Seam Inspection/Repair

SERVICE INFORMATION LETTER RECORD

25-82 / R5 16 Oct 2001 14 Mar 2003 Recommended Hydrostatic Test

25-85 6 May 1991 28 Jun 2007 B737 Evacuation System, Pressure

25-92 5 Nov 1993 14 Mar 2003 Seam Wicking

25-98 / R5 12 Nov 2007 13 Mar 2009 Maintenance Interval Recommen-

25-102 / R26 31 Jan 2014 1 Aug 2014 Authorized Repair/Service Facilities

25-113 / R1 12 Nov 1999 14 Mar 2003 Instructions for Replacing an Indi-

25-140 / R1 29 Nov 2000 28 Jun 2007 Implementation of Carbon Reser-

25-152 2 Mar 2001 14 Mar 2003 Improved Heat Reflective Coating

25-160 / R1 20 Jun 2003 10 Oct 2003 Use of Teflon Tape as a Sealant on

25-181 / R11 12 Apr 2013 1 Aug 2014 Implementation of New Valve/Reg-

25-183 / R1 2 Nov 2004 28 Jun 2007 Implementation of New Reservoir

25-193 / R1 24 Nov 2004 28 Jun 2007 Pentabromodiphenyl and Octabro-

25-199 15 Dec 2004 28 Jun 2007 Hydrostatic Test Machine, TO4853,

25-210 20 Mar 2006 28 Jun 2007 Spare Adhesive Nomenclature and

25-211 20 Mar 2006 28 Jun 2007 Maintenance Release Record

25-222 / R3 4 Nov 2011 13 Apr 2012 Methodolgy of Serial Numbers

25-228 / R2 4 Aug 2008 13 Mar 2009 Hose Assembly Product Improve-

25-243 29 May 2009 12 Feb 2010 Inside Coating of Evacuation Sys-

25-244 3 Aug 2009 12 Feb 2010 Change of Address

25-252 / R1 14 May 2010 13 Apr 2012 Replacement of Fire Retardant

LIST OF EFFECTIVE PAGES SECTION PAGE DATE

SECTION PAGE DATE SECTION PAGE DATE

Testing and 118 13 Nov 2015 Disassembly 315 13 Nov 2015

Disassembly 301 13 Nov 2015 Check 501 13 Nov 2015

SECTION PAGE DATE SECTION PAGE DATE

Repair 601 13 Nov 2015 Repair 632 13 Nov 2015

SECTION PAGE DATE SECTION PAGE DATE

Repair 664 13 Nov 2015 Special Tools 911 13 Nov 2015

A. This manual provides Description, Operation, Disassembly, Assembly,

Zodiac Aero Evacuation Systems

Testing and Fault Isolation 22 July 1991

A. Refer to Zodiac Aero Evacuation Systems (ZAES) Component Mainte-

Aft Door (Automatic 61621-469 P-11990 61768-101 25-65-20

4. Abbreviations and Symbols

5. Listing of Authorized Service Centers

For a complete list of authorized service centers refer to S. I. L. 25-102.

6. Identifying Revised Material

NOTE: A revision to a page is defined as any change to the printed

7. Maintenance Inspection Log/Maintenance Release Record

A. A maintenance inspection log/record is shipped with each system and

8. Summary of Zodiac Aero Evacuation Systems Maintenance Recommendations

A. For Evacuation Systems perform the following every 3 years up to and

* If the inflatable, hose, and applicable life-limited items are replaced at

B. For Inflation Systems perform the following every three years**.

(1). Verify incorporation of all Technical Publication Index (TPI) avail-

*Reference applicable DOT specification or special permit on reservoir for