US Airways Boeing 737-400 Airest 5 Passenger Seat Component Maintenance Manual 25-40-61

Description

US Airways Boeing 737-400 Airest 5 Passenger Seat Component Maintenance Manual 25-40-61

This is the B/E Aerospace Component Maintenance Manual (CMM) 25-40-61 issued for US Airways Boeing 737-400 aircraft fitted with Airest 5 tourist-class triple passenger seats in the 86817 and 86885 series. It is the shop-level document used to keep those seats serviceable – covering the seat structure, recline systems, armrests and modules, foodtrays, fireblocking, leg assemblies and track hardware from teardown through reassembly. The manual carries Revision 1 (dated November 16, 2001) on top of the original Revision 0 (February 23, 2001), and it also incorporates the temporary revision notices TR-1.0 through TR-2.07 that were issued against it. Aircraft maintenance libraries working 737-400 cabin interiors will recognise 25-40-61 as the controlling document for these seat assemblies.

File Details

• Manual type: Component Maintenance Manual (CMM) with Illustrated Parts List
• Manufacturer: B/E Aerospace, Seating Products Group, Winston-Salem, North Carolina
• Aircraft: US Airways Boeing 737-400
• Seat family: Airest 5, tourist class triples, 86817 and 86885 series
• Manual number: 25-40-61
• Document ID: 2482 / US Airways
• Revision: Revision 1, dated November 16, 2001 (supersedes Revision 0, February 23, 2001)
• Temporary revisions included: TR-1.0, TR-2.0, TR-2.01, TR-2.02, TR-2.03, TR-2.04, TR-2.05, TR-2.06 and TR-2.07
• Language: English
• Format: PDF

Chapters Covered

• Description and Operation – general seat description, seat operation, seat dimensions (Figures 2-1 through 2-10), fireblocking liner information, dress covers and cushions
• Testing and Fault Isolation – seat back recline mechanism checks, breakover adjustment check, seat attachment to aircraft, Fault Isolation Table 1000-1
• Disassembly – triple seat 86817/86885 series, seat bottom cushion/liner assembly 42716 series, back assembly 42779 and 42909 series, BFE housing AFP55-0063-01, foodtray assembly 42751 series, bi-fold foodtray assembly 42844 series, recline lock and shackle installations 42747 series, back installations 43063 and 43064 series
• Disassembly (continued) – endbay assembly 42974 series, special purpose endbay assembly 42975 series, armrest assembly 42658 series, HMAR armrest assembly 42767 series, endbay module 42837 series, centerbay module 42838 series, leg assembly 42652 series, leg assembly with mux box 42913 series
• Cleaning – cleaning materials and usage table, upholstery cleaning procedures for spots and heavy stains, fireblocking liner cleaning, cushion cleaning, metal parts, fabric-backed vinyls, leathers, plastics, PCU cleaning, painted surfaces, Langenthal Zirpro wool dry cleaning
• Inspection/Check – checking methods, check procedures, hardware and finish inspection
• Repair – recline control replacement, recline lock adjustment and replacement, clutch engagement adjustment, breakover adjustment, leg replacement criteria, repair of damaged fireblocking liners including seam repair and hole patching
• Assembly – installation of leg assembly, storage instructions, assembly of all seat subassemblies mirroring the disassembly breakdown
• Fits and Clearances – track studs, wear criteria, track stud and GO-NO-GO gauge, back mounted foodtray settings, in-arm foodtray adjustment, back adjustment in full upright and recline position, hydrolok stroke limit adjustment
• Torque Tables 8001 (fine thread series), 8002 (coarse thread series) and 8003 (threaded fasteners not specified)
• Special Tools – aircraft seat track fixture, GO-NO-GO track stud adjustment gauge T/N 90-I-405-CF, anti-rattle track adjustor wrench T/N 97122001
• Illustrated Parts List – Figure 1 Triple Seat Assembly, Figure 6 Bottom Cushion/Liner Assembly 42716 series, Figure 7 Back Assembly 42779 and 42909 series, Figure 8 BFE Housing AFP55-0063-01, Figure 9 Foodtray Assembly 42751 series, Figure 10 Bi-Fold Foodtray Assembly 42844 series
• Illustrated Parts List (continued) – Figure 12 Recline Lock and Shackle Installation 42747 series and Back Installations 43063 and 43064 series, Figure 13 Endbay Assembly 42974 series, Figure 14 Special Purpose Endbay Assembly 42975 series, Figure 15 Armrest Assembly 42658 series, Figure 16 HMAR Armrest Assembly 42767 series, Figure 17 Endbay Module 42837 series, Figure 18 Centerbay Module 42838 series, Figure 19 Leg Assembly 42652001, Figure 20 Leg Assembly with Mux Box 42913001, Alpha Numeric Index

Taken as a whole, this Component Maintenance Manual gives a seat shop everything needed to strip, inspect, clean, repair and rebuild the Airest 5 triple seats used in US Airways 737-400 cabins. Every disassembly and assembly step is cross-referenced to a numbered item in the Illustrated Parts List, so a technician can move from a procedure paragraph straight to the exploded drawing that shows where the part sits and what fasteners hold it. Wear limits, recline geometry, foodtray height settings and hydrolok stroke limits are called out numerically, and the three torque tables remove the guesswork from bolt and nut tightening on fine-thread, coarse-thread and unspecified fasteners. The fireblocking liner section in particular matters because it explains what can and cannot be done to a liner without compromising its thermal protection capability.

Temporary Revisions Folded Into This Manual

Several of the changes carried in this file are worth knowing about before you start work, because they change which part numbers are called out in the Illustrated Parts List. TR-2.06 replaced the older hook and pile peel part numbers with 3M adhesive hook and loop materials across the triple seat assembly, back assembly, endbay module and centerbay module. TR-2.07 updated setscrew part numbers in Figure 9 Foodtray Assembly, Figure 18 Centerbay Module Assembly, and Figures 19 and 20 Leg Assemblies. TR-2.05 added inboard leg-to-aisle seat dimensions per envelope drawings 35426 and 35482. TR-2.03 identified alternate and alternate-preferred part numbers for the literature springs and literature tubes, and TR-2.02 superseded aft back pad assemblies with new aft pad part numbers. TR-2.0 recorded that dome washer P/N 98072001 was superseded by cup washer P/N 98514001 on the leg assemblies. If you are ordering parts against this document, use the superseded and superseding notes in the parts lists rather than the older revision.

What This Manual Enables You to Do

With this Component Maintenance Manual in hand, a maintenance team can perform full seat overhauls on the 86817 and 86885 series tourist-class triples, correct recline faults, replace or adjust recline locks and hydroloks, repair breakover mechanisms, replace armrest structures and modules, service foodtrays and bi-fold foodtrays, and rebuild leg assemblies including track fittings and anti-rattle nuts. Fault isolation is handled through a structured table that pairs a symptom – a recline control push button that will not move, a seat back that fails to lock, a seat that will not sit securely on the floor tracks – with the probable cause and the corrective action, so the diagnostic path is laid out rather than improvised. Because the manual also covers cleaning agents for upholstery, fireblocking liners, plastics, metal parts and PCUs, it supports the cosmetic and refurbishment side of seat work as well as the mechanical repair side.

Getting the procedures and the numbers right matters more than usual on passenger seating, because recline throw is regulated, breakover force and exit row restrictions are safety-critical, and fireblocking liner integrity affects thermal performance. Working from an uncontrolled or incomplete manual on this hardware risks leaving a seat out of specification or a liner no longer compliant. This PDF delivers the complete document set – base manual plus all temporary revisions – so the part numbers, torque values and adjustment figures you work from are the current ones for these seats.

Delivery

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The file is supplied as an instant PDF download with no shipping and no waiting on a courier. Once payment clears you have the whole manual straight away, and you can keep it on a workshop laptop, a tablet on the hangar floor, or a phone in your pocket, and print any page you need for the bench. Nothing here is locked to a single device or a single viewing.