Installation of the Flex Shaft [PW11]

TASK 78-31-07-400-801-A
Installation of the Flex Shaft

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	AR	WARNING NOTICE(S)
No specific	1	WRENCH - TORQUE
No specific	Torque wrench: range to between 35 and 31.5 lbf.in (0.40 and 0.36 m.daN )
No specific	Torque wrench: range to between 945 and 855 lbf.in (10.68 and 9.66 m.daN )
No specific	Torque wrench: range to between 2100 and 1900 lbf.in (23.73 and 21.47 m.daN )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.PU1-0001)	lint-free cotton cloth
(Material No.PU10-0009)	male square drive
(Material No.PU10-0022)	male square drive
(Material No.PU6-0003)	lubricant

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing of the Fan Cowl Doors
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-31-00-710-805-A	Operational Test of Thrust Reverser with MCDU
TASK 78-31-00-710-805-A-01	Thrust Reverser Cycling Test (Engine Running)
Flex Shaft
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
TASK 29-10-00-864-001-A	Depressurize the Green Hydraulic System
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 29-14-00-614-002-A	Pressurization of the Hydraulic Reservoirs through the Ground Connector
TASK 29-14-00-614-002-A-01	Pressurization of the Hydraulic Reservoirs with the Auxiliary Power Unit (APU)
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
TASK 29-10-00-864-002-A	Depressurize the Yellow Hydraulic System
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 29-14-00-614-002-A	Pressurization of the Hydraulic Reservoirs through the Ground Connector
TASK 29-14-00-614-002-A-01	Pressurization of the Hydraulic Reservoirs with the Auxiliary Power Unit (APU)

3. Job Set-up
Subtask 78-31-07-941-051-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Make sure that you did the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833)

Subtask 78-31-07-010-051-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR
(2) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position.

Subtask 78-31-07-864-051-A ** ON A/C NOT FOR ALL

C. Depressurization of the Aircraft Hydraulic Systems
(1) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the applicable system:
(a) On the overhead panel, on HYD/FUEL panel 40VU.
(b) On the ground service panel of the applicable hydraulic system.
(2) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
(a) Make sure that the Green hydraulic system is depressurized (Ref. AMM TASK 29-10-00-864-001).
(b) Make sure that the reservoir of the Green hydraulic system is depressurized (Ref. AMM TASK 29-14-00-614-001).
(3) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
(a) Make sure that the Yellow hydraulic system is depressurized (Ref. AMM TASK 29-10-00-864-002).
(b) Make sure that the reservoir of the Yellow hydraulic system is depressurized (Ref. AMM TASK 29-14-00-614-001).

Subtask 78-31-07-040-051-A ** ON A/C NOT FOR ALL

D. Deactivation of the Thrust Reverser System for Ground Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Make sure that you did the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-805).

4. Procedure

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

Subtask 78-31-07-420-050-A ** ON A/C NOT FOR ALL

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS NECESSARY.

A. Installation of the Flex Shaft and Deploy Tube

NOTE: This procedure is for the flex shaft and deploy tube on the left thrust reverser door. The flex shaft and deploy tube on the right thrust reverser door is the same.

(1) Removal of the protection covers

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(a) Remove the CAP - PROTECTION from the coupling nuts on the deploy tube (2), the fitting on the locking actuator, and the fitting on the feedback locking actuator.
(2) Make sure that the locking actuator and the feedback locking actuator are locked in the fully stowed position.
(3) If one or both the locking actuator and feedback locking actuator are not in the fully stowed position, do the following:

CAUTION: DO NOT APPLY A TORQUE OF MORE THAN 70 LBF-IN (0.79 m.daN) WHEN YOU ADJUST THE ACTUATOR. TOO MUCH TORQUE CAN CAUSE DAMAGE TO THE ACTUATOR.

(a) For the locking feedback actuator, do the following:
1 Retract the locking feedback actuator to the locked position.
2 Use the male square drive (Material No.PU10-0022) 0.20 in. (5.08 mm) and the WRENCH - TORQUE.
3 Remove the male square drive (Material No.PU10-0022) 0.20 in. (5.08 mm) from the left locking feedback actuator (1).
(b) For the locking actuator, do the following:
1 Turn the Manual Drive Unit (MDU) lever to the unlocked position.
2 Put the male square drive (Material No.PU10-0009) 0.375 in. (9.52 mm) in the MDU square drive engagement.
3 Turn the MDU and retract the left locking actuator to the locked position.

NOTE: Turn the MDU on the left thrust reverser half clockwise to retract the translating sleeve. Turn the manual drive unit on the right thrust reverser half counterclockwise to retract the translating sleeve.

4 Remove the male square drive (Material No.PU10-0009) 0.375 in. (9.52 mm) from the MDU.
5 Rotate the MDU lever to the locked position.
(4) Apply material as follows:

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

(a) Apply a thin layer of lubricant (Material No.PU6-0003) to the threads of the two coupling nuts on the deploy tube (2).
(5) Put the deploy tube (2) between the actuators so that one end fitting is at the locking actuator and the other end at the locking feedback actuator.
(6) Loosely connect the deploy tube (2) coupling nut to the locking feedback actuator.
(7) Make sure that you engage at least three full threads to hold the weight of the deploy tube (2).

NOTE: Do not tighten the deploy tube (2) coupling nut at the locking feedback actuator.

NOTE: Do not connect the deploy tube (2) to the locking actuator.

(8) Clean the flex shaft (1) with a clean lint-free cotton cloth (Material No.PU1-0001) .
(9) Put the flex shaft (1) in the deploy tube (2) from the free end at the locking actuator toward the locking feedback actuator.
(10) Installation of the deploy tube.

CAUTION: DO NOT LET THE FLEX SHAFT FALL OUT OF THE DEPLOY TUBE. IF YOU DO, DAMAGE TO THE FLEX SHAFT CAN OCCUR.

(a) Have one person hold the free end of the deploy tube (2) and the flex shaft (1) and remove the deploy tube (2) coupling nut at the locking feedback actuator.
(b) Engage the end of the flex shaft (1) into the locking feedback actuator socket.
(c) Make sure that the flex shaft (1) does not twist more than a quarter of a turn clockwise during the installation.
(d) Loosely connect the deploy tube (2) coupling nut to the locking feedback actuator again. Do not tighten the coupling nut.
(e) Make sure that you engage at least three full threads.
(11) Installation of the flex shaft (1) in the feedback locking actuator

CAUTION: KEEP TWISTS OF THE FLEX SHAFT TO A MINIMUM. IF THE FLEX SHAFT TWISTS MORE THAN 1/4 TURN WHEN YOU INSTALL IT, THE FEEDBACK LOCKING ACTUATOR AND THE LOCKING ACTUATOR WILL NOT BE CORRECTLY SYNCHRONIZED. THIS CAN CAUSE THE TRANSLATING SLEEVE TO NOT MOVE FREELY DURING OPERATION.

(a) Install the bottom end of the flex shaft (1) in the locking actuator near the bottom of the thrust reverser.
(b) If necessary, manually turn the flex shaft (1) up to 1/8 turn counterclockwise to make sure that it correctly engages with the locking actuator. Do not turn the flex shaft (1) too much.
(c) Align the deploy tube (2) with the actuator alignment keyways on the locking actuator fitting.
(d) Connect the deploy tube (2) to the locking actuator.
(e) Tightening the top coupling nut and the bottom B-nut.

CAUTION: HOLD THE CONNECTOR ON THE ACTUATORS WITH A WRENCH WHILE YOU TIGHTEN OR LOOSEN THE COUPLING NUTS OF THE DEPLOY TUBE. IF YOU DO NOT OBEY THIS INSTRUCTION, DAMAGE CAN OCCUR.

1 TORQUE the top coupling nut on the deploy tube (2) of the feedback locking actuator to between 945 and 855 lbf.in (10.68 and 9.66 m.daN )

.
2 TORQUE the bottom B-nut on the deploy tube (2) of the locking actuator to between 2100 and 1900 lbf.in (23.73 and 21.47 m.daN )

.
(f) Make sure that you cannot see the threads on the locking actuator.
(12) Put the two clamp inserts (6) and clamp assemblies (3) on the deploy tube (2).
(13) Attach the two clamp inserts (6) and clamp assemblies (3) to the gussets near the top and the bottom of the thrust reverser.
(14) Use the four bolts (5) and washers (4).
(15) Make sure that the clamp inserts (6) are in the clamp assemblies (3). Do not torque the bolts at this time.
(16) Put the three clamps (9) on the deploy tube (2).
(17) Attach the three clamps (9) to the gussets on the thrust reverser with the three bolts (8) and washers (7). Do not torque the bolts at this time.
(18) Adjust the deploy tube (2) to keep preload to a minimum.
(19) TORQUE the four bolts (5) to between 35 and 31.5 lbf.in (0.40 and 0.36 m.daN )

.
(20) TORQUE the three bolts (8) to between 35 and 31.5 lbf.in (0.40 and 0.36 m.daN )

5. Close-up
Subtask 78-31-07-863-050-A ** ON A/C NOT FOR ALL

A. Pressurization of the Aircraft Hydraulic Systems
(1) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
(a) Pressurize the reservoir of the Green hydraulic system (Ref. AMM TASK 29-14-00-614-002).
(2) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
(a) Pressurize the reservoir of the Yellow hydraulic system (Ref. AMM TASK 29-14-00-614-002).

Subtask 78-31-07-440-050-A ** ON A/C NOT FOR ALL

B. Do the reactivation of the thrust reverser system after ground maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 78-31-07-410-050-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the access platform(s).
(3) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR
(4) Remove the WARNING NOTICE(S).

Subtask 78-31-07-710-051-A ** ON A/C NOT FOR ALL

D. Test
(1) Do the operational test of the thrust reverser system with the Multipurpose Control and Display Unit (MCDU) (bleeding) (Ref. AMM TASK 78-31-00-710-805).
(a) Look for leakage of hydraulic from the connectors of the deploy tube (2).

[Rev.10 from 2021] 2026.04.01 03:31:22 UTC