Installation of the C-Duct Non-Locking Actuator [IAE]

TASK 78-32-48-400-010-A
Installation of the C-Duct Non-Locking Actuator

ZONE: 400
FIN: 1000EM1 ** ON A/C NOT FOR ALL
FIN: 1000EM2 ** ON A/C NOT FOR ALL

1. Reason for the Job
This task supplies the data to install the left and the right C-duct non-locking actuators.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	AR	CONTAINER - CLEAN, APPLICABLE
No specific	AR	DRIVE 3-16 IN (0,190 IN - 4,763 MM) - SQUARE
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 35 and 30 lbf.in (0.40 and 0.34 m.daN )
No specific	Torque wrench: range to between 80 and 60 lbf.in (0.90 and 0.68 m.daN )
No specific	Torque wrench: range to between 90 and 75 lbf.in (1.02 and 0.85 m.daN )
No specific	Torque wrench: range to between 240 and 210 lbf.in (2.71 and 2.37 m.daN )
No specific	Torque wrench: range to between 245 and 215 lbf.in (2.77 and 2.43 m.daN )
No specific	Torque wrench: range to between 936 and 852 lbf.in (10.58 and 9.63 m.daN )
IAE1N20049	2	PIN - LOCKOUT ACTUATOR

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.06BHG1)	Silicone Sealant-Firewall High Temp. -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [1000EM1] (ENGINE-1)
437AL, 438AR, 451BL, 452BR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR, 461BL, 462BR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 12-12-29-611-001-A	Fill the Hydraulic Fluid Reservoir with a Hand Pump
TASK 12-12-29-611-002-A	Fill the Hydraulic Fluid Reservoir with a Hydraulic Service Cart
TASK 70-23-11-911-013-A	General Torque Tightening Techniques
TASK 70-23-15-912-010-A	Connection of Electrical Connectors
TASK 71-13-00-010-010-A	Opening of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 71-13-00-410-010-A	Closing of the Fan Cowls 437AL(447AL),438AR(448AR)
TASK 78-30-00-040-012-A	Deactivation of the Thrust Reverser Hydraulic Control Unit (HCU) for Ground Maintenance
TASK 78-30-00-440-012-A	Re-activation of the Thrust Reverser Hydraulic Control Unit (HCU) after Ground Maintenance
TASK 78-30-00-820-010-A	Rigging of the Thrust Reverser System
TASK 78-31-00-710-041-A	Operational Test of the Thrust Reverser System with the CFDS
TASK 78-31-00-710-041-A-02	Operational test of the Thrust Reverser without the CFDS and Engine Running
TASK 78-31-00-710-041-A	Operational Test of the Thrust Reverser System with the CFDS
TASK 78-31-00-710-041-A-02	Operational test of the Thrust Reverser without the CFDS and Engine Running
TASK 78-32-00-860-011-A	Manual Retraction of the Thrust Reverser Translating Sleeves
TASK 78-32-48-220-801-A	Check for Actuator Stow Tube Clearance
TASK 78-32-48-400-010-A	Installation of the C-Duct Non-Locking Actuator
Actuator Access Panels
Actuator Forward and Aft Supports and Rod-End Connection
Actuator Connections - Left Side
Locking Actuator

3. Job Set-up
Subtask 78-32-48-860-050-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) On the center pedestal, on the ENG panel 115VU, make sure that a WARNING NOTICE(S) is in position to tell persons not to start the engine.
(2) On the overhead maintenance panel 50VU, make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off. Make sure that a WARNING NOTICE(S) is in position to tell persons not to energize the FADEC 1(2).
(3) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position.

Subtask 78-32-48-010-054-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR
(2) Make sure that the access panel for the applicable actuator is open:

Actuator Access Panels ** ON A/C NOT FOR ALL

(a) FOR [1000EM1] (ENGINE-1)
451BL 452BR
(b) FOR [1000EM2] (ENGINE-2)
461BL 462BR

Subtask 78-32-48-040-051-A ** ON A/C NOT FOR ALL

C. Make sure that the thrust reverser Hydraulic Control Unit (HCU) is deactivated (Ref. AMM TASK 78-30-00-040-012).

4. Procedure
Subtask 78-32-48-420-050-A ** ON A/C NOT FOR ALL

A. Installation of the Non-locking Actuator

Actuator Forward and Aft Supports and Rod-End Connection ** ON A/C NOT FOR ALL

PRE SBN 78-0199
(1) Install the seal (40) over the end of the actuator (15). Put the seal against the plate at the base of the actuator gimbal.
(2) Align the rod end mount hole so that it is parallel with the actuator pin mount holes in the actuator. Keep the rod end in this position during the remaining installation procedure.
(3) Manually move the actuator to the fully closed (stowed) position (Ref. AMM TASK 78-32-00-860-011).
(4) Install the actuator in the C-duct. Put it carefully through the structure and keep the correct rod end position.

Subtask 78-32-48-410-050-C ** ON A/C NOT FOR ALL

B. Connection of the Non-Locking Actuator to the Forward and Aft Support

Actuator Forward and Aft Supports and Rod-End Connection ** ON A/C NOT FOR ALL

Post SBN 78-0199
(1) Install the two actuator pins.

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

(a) Push the actuator (15) to the rear to compress the seal (40). Install the two actuator pins (37) that attach the actuator to the forward support ring (39).
(b) Install the two retainer pins (38) in the forward support ring.
(c) Mix the Silicone Sealant-Firewall High Temp. - (Material No.06BHG1) . Refer to manufacturer's instructions.
(d) Apply Silicone Sealant-Firewall High Temp. - (Material No.06BHG1) to retainer pin (38) and retainer pin holes. Do not apply to threaded area.
(e) Let the sealant cure.

NOTE: Fully cured silicone sealant may not be necessary under repair conditions. The uncured sealant is structurally and functionally acceptable.

(2) Install the loose cushion half.
(a) Install the loose cushion half (36) on the actuator (15). Be careful to keep the correct rod end position.
(b) Align the marks on the cushion halves.
(c) Install the clamp half (49) with two bolts (43) and (48), four washers (45) and (46) and two nuts (44) and (47).
(d) TORQUE the nut (44) to between 35 and 30 lbf.in (0.40 and 0.34 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
(e) TORQUE the nut (47) to between 90 and 75 lbf.in (1.02 and 0.85 m.daN )

(Ref. AMM TASK 70-23-11-911-013).

Subtask 78-32-48-420-051-A ** ON A/C NOT FOR ALL

C. Attach the actuator rod end to the translating sleeve bracket

Actuator Forward and Aft Supports and Rod-End Connection ** ON A/C NOT FOR ALL

CAUTION: YOU CANNOT CORRECTLY RIG THE THRUST REVERSER IF YOU DO NOT KEEP THE ROD END FROM TURNING WHILE YOU EXTEND THE ACTUATOR.

(1) Hold the rod end so it aligns with (will fit into) the translating sleeve bracket.
(2) Use a DRIVE 3-16 IN (0,190 IN - 4,763 MM) - SQUARE in the flexshaft socket of the actuator to extend the actuator until the rod end fits into the translating sleeve bracket and you can install the bushing (32) and bolt (31). Do not torque the bolt now.
(3) Put a CONTAINER - CLEAN, APPLICABLE below the hydraulic connections.

Subtask 78-32-48-630-050-A ** ON A/C NOT FOR ALL

D. Remove the caps from the tubes, the hoses and the actuator.

Actuator Connections - Left Side ** ON A/C NOT FOR ALL

WARNING: DO NOT GET HYDRAULIC FLUID ON YOUR SKIN, IN YOUR EYES OR IN YOUR MOUTH. HYDRAULIC FLUID IS POISONOUS AND CAN GO THROUGH YOUR SKIN AND INTO YOUR BODY. FLUSH HYDRAULIC FLUID FROM YOUR EYES, MOUTH OR SKIN WITH WATER. GET MEDICAL AID IF YOU GET HYDRAULIC FLUID IN YOUR EYES OR MOUTH.

CAUTION: DO NOT LET HYDRAULIC FLUID FALL ON THE ENGINE. UNWANTED HYDRAULIC FLUID MUST BE REMOVED IMMEDIATELY WITH A CLEAN LINT FREE CLOTH. THE FLUID CAN CAUSE DAMAGE TO THE SURFACE PROTECTION AND TO SOME PARTS.

(1) Remove the caps from the lower flexshaft/tube (17) and the cross-over flexshaft/hose (14).
(2) Remove the caps from the lower hydraulic tube (16) and the cross-over hose (13).
(3) Remove the caps from the actuator hydraulic connections.

Subtask 78-32-48-420-052-A ** ON A/C NOT FOR ALL

E. Install the tubes and hoses

Actuator Connections - Left Side ** ON A/C NOT FOR ALL

CAUTION: DO NOT TURN THE FLEXSHAFT MORE THAN ONE-EIGHTH TURN TO ALIGN IT WITH THE SOCKET.

(1) Install the cross-over flexshaft/hose (14) on the actuator (15).
(a) Put the end of the flexshaft (19) into the actuator socket.
(b) Connect the hose nut of the cross-over flexshaft/hose to the actuator.
(c) Torquing of the hose nut

CAUTION: BEFORE INSTALLING THE FLEXSHAFT/TUBE (14), MAKE SURE BOTH TRIANGULAR-FLANGED-ADAPTERS ARE ATTACHED TO THE ACTUATOR WITH THREE BOLTS AND LOCKWIRE. IF THERE ARE ANY SIGNS THAT THE TRIANGULAR-FLANGED-ADAPTERS OR LOCKWIRE HAVE BEEN REMOVED OR TAMPERED WITH, THE ACTUATOR SHOULD BE REPLACED BECAUSE DAMAGE COULD OCCUR TO THE ACTUATOR.

1 TORQUE the hose nut to between 936 and 852 lbf.in (10.58 and 9.63 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
(2) Install the cross-over hydraulic hose (13) on the actuator (15).
(a) Connect the hose nut of the cross-over hydraulic hose to the actuator.
(b) TORQUE the hose nut to between 245 and 215 lbf.in (2.77 and 2.43 m.daN )

(Ref. AMM TASK 70-23-11-911-013).
(3) Install the lower flexshaft/tube (17) to the actuator (15).

(a) Put the flexshaft (20) into the actuator socket.
(b) Connect the tube nut of the lower flexshaft/tube to the actuator.
(c) TORQUE the tube nut to between 936 and 852 lbf.in (10.58 and 9.63 m.daN )

(Ref. AMM TASK 70-23-11-911-013).

NOTE: Hold the flats on the end of the lower flexshaft/tube when you torque the tube nut.

(4) Install the lower hydraulic tube (16) on the actuator (15)
(a) Connect the tube nut of the lower hydraulic tube to the actuator.
(b) TORQUE the tube nut to between 240 and 210 lbf.in (2.71 and 2.37 m.daN )

(Ref. AMM TASK 70-23-11-911-013).

NOTE: Hold the flats on the end of the lower hydraulic tube when you torque the nut.

(c) Install the tube clamps (removed during the removal task) on the lower hydraulic tube (1) (Ref. AMM TASK 78-32-48-400-010).
(5) Remove the container and discard the drained hydraulic fluid.

Subtask 78-32-48-630-051-A ** ON A/C NOT FOR ALL

F. Remove the caps from the electrical connector (18) on the electrical harness and from the actuator (15).

Actuator Connections - Left Side ** ON A/C NOT FOR ALL

Subtask 78-32-48-420-053-A ** ON A/C NOT FOR ALL

G. Install the electrical connector

Actuator Connections - Left Side ** ON A/C NOT FOR ALL

(1) Connect the electrical connector (18) to the receptacle on the actuator (15) (Ref. AMM TASK 70-23-15-912-010).
(2) Tighten the electrical connector by hand plus one-eighth turn.

Subtask 78-32-48-820-051-A ** ON A/C NOT FOR ALL

H. Rig of the Thrust Reverser System
(1) Rig the translating sleeves, actuators, actuator supports and translating sleeve aft double latches (Ref. AMM TASK 78-30-00-820-010).
(2) TORQUE the rod end retaining bolts (31) to between 80 and 60 lbf.in (0.90 and 0.68 m.daN )

Subtask 78-32-48-220-051-A ** ON A/C NOT FOR ALL

I. Perform and record a check clearance between the actuator stow tube and the fan cowl door (Ref. AMM TASK 78-32-48-220-801).
(1) If the actuator is POST SBN 70-0970, no check is necessary.
(2) If clearance is less than 0.04 in. (1.02 mm) continue with (Ref. AMM TASK 78-32-48-220-801) and shim the torque box until clearance reaches at least 0.04 in. (1.02 mm).

5. Close-up
Subtask 78-32-48-410-051-A ** ON A/C NOT FOR ALL

A. Install the actuator access panels:

Actuator Access Panels ** ON A/C NOT FOR ALL

(1) FOR [1000EM1] (ENGINE-1)
451BL 452BR
(2) FOR [1000EM2] (ENGINE-2)
461BL 462BR

Subtask 78-32-48-440-050-A ** ON A/C NOT FOR ALL

B. Activate the HCU (Ref. AMM TASK 78-30-00-440-012).

Subtask 78-32-48-870-050-A ** ON A/C NOT FOR ALL

C. Bleed the air from the thrust-reverser hydraulic-actuation system

Locking Actuator ** ON A/C NOT FOR ALL

CAUTION: YOU MUST MOVE THE LOCK LEVERS OF THE TWO LOCKING ACTUATORS AFT TO THE UNLOCKED POSITION BEFORE YOU BLEED THE SYSTEM. IF YOU DO NOT DO THIS, UNEVEN OPERATION OF THE TRANSLATING SLEEVES CAN CAUSE DAMAGE TO THE SYSTEM.

CAUTION: MAKE SURE THAT ALL CAUGHT AIR IS BLED FROM THE SYSTEM. IF YOU DO NOT DO THIS, CAUGHT AIR CAN CAUSE UNSATISFACTORY OPERATION OF THE TRANSLATING SLEEVES. TEN CYCLES OF TRANSLATING SLEEVE POWER EXTENSION AND RETRACTION WILL REMOVE ALL CAUGHT AIR FROM THE SYSTEM.

(1) Move the lock levers (2) of the left and the right locking actuators (1) aft to the unlocked position and install IAE1N20049 PIN - LOCKOUT ACTUATOR (3) to hold the lock levers in the unlocked position. If necessary, you can manually unstow the reverser to move the lock.
(2) Operate the system.

WARNING: MAKE SURE THAT THERE ARE NO PERSONS IN THE AREA AROUND THE THRUST REVERSER BEFORE YOU DO A POWER EXTENSION OR RETRACTION OF THE TRANSLATING SLEEVES. THE TRANSLATING SLEEVES EXTEND AND RETRACT IN 4.5 SECONDS OR LESS AND CAN CAUSE INJURY AND DAMAGE.

(a) Operate the system through ten cycles of translating sleeve power extension and retraction (Ref. AMM TASK 78-31-00-710-041).

NOTE: Due to the configuration of the thrust-reverser locking actuators, ignore the fault messages during this operational test.

(3) Removal of pins.

CAUTION: THE LOCKING ACTUATOR LOCK LEVERS MUST BE IN THE FORWARD LOCKED POSITION FOR FLIGHT OPERATION.

(a) Remove IAE1N20049 PIN - LOCKOUT ACTUATOR (3) from the locklevers (2) of the left and the right locking actuators (1) and move the lock levers to the locked position.
(4) Refill the green hydraulic reservoir for engine 1 (yellow for engine 2) (Ref. AMM TASK 12-12-29-611-001) or (Ref. AMM TASK 12-12-29-611-002).

Subtask 78-32-48-410-052-A ** ON A/C NOT FOR ALL

D. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the fan cowls (Ref. AMM TASK 71-13-00-410-010):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR
(3) Remove the WARNING NOTICE(S).
(4) Remove the access platform(s).

Subtask 78-32-48-710-051-A ** ON A/C NOT FOR ALL

E. Operational Test
(1) Do an operational test of the thrust reverser system (Ref. AMM TASK 78-31-00-710-041).

NOTE: As an alternative procedure, you can do the operational test without the CFDS (Ref. AMM TASK 78-31-00-710-041).

[Rev.10 from 2021] 2026.04.01 03:28:48 UTC