Removal of the Thrust Reverser Cowl Doors [CFML]

TASK 78-32-11-000-803-A
Removal of the Thrust Reverser Cowl Doors

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE SHUTDOWN. USE APPLICABLE THERMAL GLOVES. THE ENGINE PARTS CAN STAY HOT FOR ONE HOUR AFTER SHUTDOWN AND CAN BURN YOU.

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

CAUTION: THIS PART IS A REMOVABLE STRUCTURAL COMPONENT (RSC), WHICH CAN BE MOVED BETWEEN AIRCRAFT. THUS IT CAN HAVE DIFFERENT OPERATION CONDITIONS AND A DIFFERENT LIFE RECORD (FLIGHT HOURS/FLIGHT CYCLES/CALENDAR) FROM THE AIRCRAFT IT IS INSTALLED ON OR REMOVED FROM. THE OPERATOR IS RESPONSIBLE FOR THE SPECIFIC TRACKING AND CONTINUED AIRWORTHINESS OF REMOVABLE STRUCTURAL COMPONENTS. INCORRECT MAINTENANCE OF THESE COMPONENTS CAN CAUSE A RISK FOR THE FLIGHT SAFETY.

ZONE: 210
ZONE: 400

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)
No specific	AR	CAP - BLANKING
No specific	1	CONTAINER 5 L (1.32 USGAL)
No specific	1	CRANE 1000KG (2200 LB)
No specific	1	MALLET - SOFT FACE
No specific	AR	PLUG - BLANKING
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	1	SCALE 1000 KG (2200 LB)
No specific	AR	WARNING NOTICE(S)
98N7830H002-000	1	THRUST REVERSER DOLLY
98N7830H022-000	1	THRUST REVERSER HOISTING FRAME 2
98N7830H028-000	1	THRUST REVERSER HINGE BOLT BULLETS

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
210	CKPT,FWD COMPT BHD TO FLT COMPT BULKHEAD
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

C. Referenced Information

REFERENCE	DESIGNATION
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 71-13-00-010-803-A	Opening of the Fan Cowl Doors
TASK 71-13-11-000-806-A	Removal of the Fan Cowl Doors
TASK 78-30-00-040-807-A	Deactivation of the Thrust Reverser System for Nacelle Maintenance (ICU)
TASK 78-32-43-000-806-A	Removal of the Thrust Reverser Cascades
TASK 78-36-45-000-801-A	Removal of the Thrust Reverser Hinge Access Panels
TASK 78-36-46-000-801-A	Removal of the Latch Access Doors
TASK 78-36-51-000-802-A	Removal of the Thrust Reverser Cowl Opening System
Thrust Reverser Cowl Doors - (PRE SPOL BD-TR-17026)
Thrust Reverser Cowl Doors - (POST SPOL BD-TR-17026)

3. Job Set-up
Subtask 78-32-11-941-065-A

A. Safety Precautions
(1) On the center pedestal, on ENG panel 115VU:
(a) Make sure that the ENG/MODE selector switch is in the NORM position.
(b) Make sure that the ENG/MASTER 1(2) control switch was in the OFF position not less than five minutes before you do this procedure.
(c) Put WARNING NOTICE(S) in position to tell persons not to operate:

The ENG/MODE selector switch, and
The ENG/MASTER 1(2) control switch.

(2) On the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put a WARNING NOTICE(S) in position to tell persons not to energize FADEC 1(2).

Subtask 78-32-11-865-057-A

B. Open, safety and tag this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C ALL
121VU	HYDRAULIC/HYD POWER/Y	3803GX	N31
123VU	Y HYD/ELEC/PUMP	3802GX	AB06
123VU	Y HYD/ELEC/ELEC PUMP/NORM	3801GX	AB03

Subtask 78-32-11-864-057-A

C. Depressurization of the Hydraulic Reservoirs

WARNING: FAILURE TO SHUT OFF AIRCRAFT HYDRAULIC SUPPLY TO THRUST REVERSER CAN RESULT IN SERIOUS INJURY TO PERSONNEL.

(1) For 4020KM1:
(a) Depressurize the Green hydraulic reservoir (Ref. AMM TASK 29-14-00-614-001).
(2) For 4020KM2:
(a) Depressurize the Yellow hydraulic reservoir (Ref. AMM TASK 29-14-00-614-001).

Subtask 78-32-11-010-082-A

D. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR.
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR.
(2) Put an ACCESS PLATFORM 2M (6 FT) in position.

Subtask 78-32-11-040-068-A

E. Deactivation of the Thrust Reverser System for Nacelle 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) Do the deactivation of the thrust reverser system for nacelle maintenance (Ref. AMM TASK 78-30-00-040-807).

Subtask 78-32-11-010-088-A

F. Remove the inner fan cowl door (Ref. AMM TASK 71-13-11-000-806).

NOTE: The removal of the inner fan cowl door is necessary only for the removal of the inner thrust reverser cowl.

4. Procedure

WARNING: DO THE STEPS THAT FOLLOW IN THE SEQUENCE GIVEN. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT CAN OCCUR.

CAUTION: DO NOT LIFT OR MOVE THE THRUST REVERSER WITH LESS THAN TWO CASCADES (BLANK-OFF INCLUDED) OR THE BLANK-OFF WITH THE DUMMY CASCADE INSTALLED. THERE MUST BE REGULAR SPACE BETWEEN THE CASCADES. IF YOU DO NOT OBEY THIS INSTRUCTION, YOU CAN CAUSE DAMAGE TO THE THRUST REVERSER STRUCTURE.

NOTE: Each half thrust reverser weighs approximately 573 lb (260 kg).

NOTE: Minimum three mechanics are necessary to install the TRU cowl door. One mechanic on the pylon, one mechanic to guide the TRU cowl door from the ground and one mechanic to operate the hoist.

NOTE: You can remove each thrust reverser cowl independently.

Subtask 78-32-11-020-057-A

A. Removal of the Left Thrust Reverser Cowl Doors
(1) Remove the 12 o'clock hinge access panel (Ref. AMM TASK 78-36-45-000-801).

NOTE: Remove only the hinge access panel that is on the same side of the half thrust reverser cowl to be removed.

(2) Disconnection of the OTT sync tube (1):
(a) Put the CONTAINER 5 L (1.32 USGAL) in position to collect the drained hydraulic fluid.
(b) Remove the screws (2) and the Omega clamps (3).
(c) Disconnect the 12 o'clock thrust reverser OTT sync tube (1) from the upper actuator on the forward frame of the left thrust reverser cowl.
(d) Disengage the internal flexshaft of the OTT sync tube (1) from the upper actuator on the forward frame of the left thrust reverser cowl actuator.
(e) Secure the internal flexshaft to the OTT sync tube (1).
(f) Install a PLUG - BLANKING on the actuator side and the hose side.
(3) Disconnection of the two hydraulic hoses (5):
(a) Put the CONTAINER 5 L (1.32 USGAL) in position to collect the drained hydraulic fluid.
(b) Disconnect the two hydraulic hoses (5).
(c) Install a PLUG - BLANKING on the actuator and hose side.
(4) Disconnection of the electrical harness:
(a) Disconnection of the electrical harness (33, 34, 35 and 36) for the left thrust reverser cowl removal:
1 Disconnect the electrical harnesses (35 and 36) from the disconnect bracket (32).
2 Disconnect the electrical harnesses (33 and 34) from the Directional Control Unit (DCU) (31).
3 Put blanking caps on the harness connectors, disconnect bracket (32) and DCU (31).
4 Loop and attach the electrical harnesses (33, 34, 35 and 36) on the pylon (8).
(5) Remove the thrust reverser cowl opening actuator (7) (Ref. AMM TASK 78-36-51-000-802).
(6) Removal of the hinge nuts from hinge pins R1 (10) and R2 (14):

WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.

(a) Remove the cotter pin (9), hinge nut (11) and washer (12) from hinge pin R1 (10).
(b) Discard the cotter pin (9).
(c) Remove the cotter pin (13), hinge nut (15) and washer (16) from the hinge pin R2 (14).
(d) Discard the cotter pin (13).
(e) Remove and discard the cotter pin (17) from the hinge pin R3 (18).
(f) Loosen the hinge nut (19) from the hinge pin R3 (18).
(g) Remove and discard the cotter pin (21) from the hinge pin R4 (22).
(h) Loosen the hinge nut (23) from the hinge pin R4 (22).
(7) Removal of the thrust reverser cowl hinge pins R1 (10) and R2 (14):

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE ADJACENT STRUCTURE AND HINGE PINS DURING THIS OPERATION.

(a) Install the 98N7830H028-000 THRUST REVERSER HINGE BOLT BULLETS (25) on the hinge pins R1 (10) and R2 (14).
(b) Use the MALLET - SOFT FACE to remove the hinge pins:
1 Remove the hinge pin R1 (10) from the hinge.
2 Remove the hinge pin R2 (14) from the hinge.
(8) Installation of the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) on the thrust reverser cowl:

CAUTION: FOR USE ON AN INBOARD COWL, MAKE SURE THAT YOU DO THE CORRECT GSE ASSEMBLY TO PREVENT INTERFERENCE WITH THE AIRCRAFT WING. READ THE INSTRUCTIONS IN THE APPLICABLE GSE INSTRUCTION MANUAL. DO NOT OBEY THIS INSTRUCTION, YOU CAN CAUSE DAMAGE TO THE THRUST REVERSER STRUCTURE.

(a) Make sure that the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 is well assembled and well equipped for the half thrust reverser to be removed. Refer to GSE notice.
(b) Connect and tighten the hoisting fittings (27) on the thrust reverser cowl hoisting point at the 6 o'clock beam (29).
(c) Connect and tighten the hoisting fittings (27) on the thrust reverser cowl hoisting point at 12 o'clock beam (28).
(d) Carefully lift the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) from its storage box.
(e) Carefully tilt the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) to the vertical position.
(f) Carefully move the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) near the thrust reverser cowl.
(g) Connect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) on the hoisting fittings (27) at the 6 o'clock beam (29). Refer to GSE notice.
(h) Connect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) on the hoisting fittings (27) at the 12 o'clock beam (28). Refer to GSE notice.
(i) Use the CRANE 1000KG (2200 LB) to put in tension the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) until the SCALE 1000 KG (2200 LB) indicates approximately 410 kg (903.90 lb).

NOTE: When the SCALE 1000 KG (2200 LB) indicates approximately 410 kg (903.90 lb), the half TR is opened at approximately an angle of 10° from the closed position.

NOTE: 410 kg (903.90 lb) is the weight of the TR half + 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2.

(9) Removal of the thrust reverser cowl hinge pins R3 (18) and R4 (22):

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE ADJACENT STRUCTURE AND HINGE PINS DURING THIS OPERATION.

(a) Remove the hinge nut (19) and washer (20) from the hinge pin R3 (18).
(b) Remove the hinge nut (23) and washer (24) from the hinge pin R4 (22).
(c) Install the 98N7830H028-000 THRUST REVERSER HINGE BOLT BULLETS (25) on the hinge pins R3 (18) and R4 (22).
(d) Use the MALLET - SOFT FACE to remove the hinge pins:
1 Remove the hinge pin R3 (18) from the hinge.
2 Remove the hinge pin R4 (22) from the hinge.

POST SPOL BD-TR-17026
(10) Remove the plug (37) from the 6 o'clock beam (29).

END OF POST SPOL BD-TR-17026
(11) Removal of the thrust reverser cowl:

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE WING OR THE ENGINE DURING THRUST REVERSER COWL MOVEMENT.

(a) Carefully move the thrust reverser cowl away from the engine with the use of the hoist and the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26).
(12) Installation of the thrust reverser cowl on the 98N7830H002-000 THRUST REVERSER DOLLY:
(a) Install the thrust reverser half on the 98N7830H002-000 THRUST REVERSER DOLLY and put the pins in position in the thrust reverser hinges.
(b) Attach the tie-down strap to hold the thrust reverser half on the 98N7830H002-000 THRUST REVERSER DOLLY.
(c) Disconnect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) from the hoisting fittings (27) at the 12 o'clock beam (28).
(d) Disconnect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) from the hoisting fittings (27) at 6 o'clock beam (29).
(e) Move the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) with the CRANE 1000KG (2200 LB) outside the 98N7830H002-000 THRUST REVERSER DOLLY area.
(f) Remove the hoist fittings (27) from the thrust reverser cowl hoisting point the 12 o'clock beam (28) and 6 o'clock beam (29).
(13) Remove all the cascades from the thrust reverser cowl (Ref. AMM TASK 78-32-43-000-806).

Subtask 78-32-11-020-060-A

B. Removal of the Right Thrust Reverser Cowl Doors
(1) Remove the 12 o'clock hinge access panel (Ref. AMM TASK 78-36-45-000-801).

NOTE: Remove only the hinge access panel that is on the same side of the half thrust reverser cowl to be removed.

(2) Remove the front and aft latch access doors (Ref. AMM TASK 78-36-46-000-801).
(3) Disconnection of the OTT sync tube (1):
(a) Put the CONTAINER 5 L (1.32 USGAL) in position to collect the drained hydraulic fluid.
(b) Remove the screws (2) and the Omega clamps (3).
(c) Disconnect the 12 o'clock thrust reverser OTT sync tube (1) from the upper actuator on the forward frame of the right thrust reverser cowl.
(d) Disengage the internal flexshaft of the OTT sync tube (1) from the upper actuator on the forward frame of the right thrust reverser cowl actuator.
(e) Secure the internal flexshaft to the OTT sync tube (1).
(f) Install a PLUG - BLANKING on the actuator side and the hose side.
(4) Disconnection of the hydraulic hoses (4) and (5):
(a) Put the CONTAINER 5 L (1.32 USGAL) in position to collect the drained hydraulic fluid.
(b) Disconnect the hydraulic hoses (4) and (5).
(c) Install a PLUG - BLANKING on the actuator and hose side.
(5) Disconnection of the electrical harness:
(a) Disconnection of the electrical harnesses (6) for the thrust reverser cowl removal:
1 Disconnect the electrical harnesses (6) from the electrical disconnect plate (30).
2 Put CAP - BLANKING on the harness connectors and disconnect plate connectors.
3 Loop and attach the electrical harnesses (6) on the forward frame.
(6) Remove the thrust reverser cowl opening actuator (7) (Ref. AMM TASK 78-36-51-000-802).
(7) Removal of the hinge nuts from hinge pins R1 (10) and R2 (14):

WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.

(a) Remove the cotter pin (9), the hinge nut (11) and the washer (12) from the hinge pin R1 (10).
(b) Discard the cotter pin (9).
(c) Remove the cotter pin (13), the hinge nut (15) and the washer (16) from the hinge pin R2 (14).
(d) Discard the cotter pin (13).
(e) Remove and discard the cotter pin (17) from the hinge pin R3 (18).
(f) Loosen the hinge nut (19) from the hinge pin R3 (18).
(g) Remove and discard the cotter pin (21) from the hinge pin R4 (22).
(h) Loosen the hinge nut (23) from the hinge pin R4 (22).
(8) Removal of the thrust reverser cowl hinge pins R1 (10) and R2 (14):

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE ADJACENT STRUCTURE AND HINGE PINS DURING THIS OPERATION.

(a) Install the 98N7830H028-000 THRUST REVERSER HINGE BOLT BULLETS (25) on the hinge pins R1 (10) and R2 (14).
(b) Use the MALLET - SOFT FACE to remove the hinge pins:
1 Remove the hinge pin R1 (10) from the hinge.
2 Remove the hinge pin R2 (14) from the hinge.
(9) Installation of the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) on the thrust reverser cowl:

(a) Make sure that the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 is well assembled and well equipped for the half thrust reverser to be removed. Refer to GSE notice.
(b) Connect and tighten the hoisting fittings (27) on the thrust reverser cowl hoisting point at the 6 o'clock beam (29).
(c) Connect and tighten the hoisting fittings (27) on the thrust reverser cowl hoisting point at 12 o'clock beam (28).
(d) Carefully lift the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) from his storage box.
(e) Carefully tilt the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) to the vertical position.
(f) Carefully move the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) near the thrust reverser cowl.
(g) Connect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) on the hoisting fittings (27) at the 6 o'clock beam (29). Refer to GSE notice.
(h) Connect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) on the hoisting fittings (27) at the 12 o'clock beam (28). Refer to GSE notice.
(i) Use the CRANE 1000KG (2200 LB) to put in tension the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) until the SCALE 1000 KG (2200 LB) indicates approximately 410 kg (903.90 lb).

NOTE: When the SCALE 1000 KG (2200 LB) indicates approximately 410 kg (903.90 lb), the half TR is opened at approximately an angle of ten degrees from the closed position.

NOTE: 410 kg (903.90 lb) is the weight of the TR half + 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2.

(10) Removal of the thrust reverser cowl hinge pins R3 (18) and R4 (22):

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE ADJACENT STRUCTURE AND HINGE PINS DURING THIS OPERATION.

CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE WING OR THE ENGINE DURING THRUST REVERSER COWL MOVEMENT.

(a) Carefully move the thrust reverser cowl away from the engine with the use of the hoist and the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26).
(12) Installation of the thrust reverser cowl on the 98N7830H002-000 THRUST REVERSER DOLLY:
(a) Install the thrust reverser half on the 98N7830H002-000 THRUST REVERSER DOLLY and put the pins in position in the thrust reverser hinges.
(b) Attach the tie-down strap to hold the thrust reverser half on the 98N7830H002-000 THRUST REVERSER DOLLY.
(c) Disconnect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 from the hoisting fittings (27) at the 12 o'clock beam (28).
(d) Disconnect the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) from the hoisting fittings (27) at 6 o'clock beam (29).
(e) Move the 98N7830H022-000 THRUST REVERSER HOISTING FRAME 2 (26) with the CRANE 1000KG (2200 LB) outside the 98N7830H002-000 THRUST REVERSER DOLLY area.
(f) Remove the hoist fittings (27) from the thrust reverser cowl hoisting point the 12 o'clock beam (28) and 6 o'clock beam (29).
(13) Remove all the cascades from the thrust reverser cowl, if necessary (Ref. AMM TASK 78-32-43-000-806).

NOTE: If the half thrust reverser cowl door will not be reinstalled on the same engine position, you should change cascades configuration. Refer to cascade configuration plate installed on forward frame.

[Rev.10 from 2021] 2026.04.01 03:35:55 UTC