THOMSON AIRWAYS LIMITED

RB211-535E4 THRUST REVERSER -

REMOVAL/INSTALLATION

Form No: 757-78-30-01 A/C Reg:

Issue: 1 Date: DECEMBER 2016 Check:
Compiled from: B757 M.M. CHAP 78-31-20 Date:
Station:

P/N OFF: S/N OFF: POSN: #___ ENG, INBOARD/OUTBOARD

P/N ON: S/N ON:

REASON FOR REMOVAL:

ADDITIONAL TASKS
REQUIRED ON REPLACEMENT
THRUST REVERSER
DURING/FOLLOWING
INSTALLATION:

THRUST REVERSER REMOVAL

ITE REQUIREMENT MECH INSP
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1 Remove the pressure from the hydraulic system (PAGEBLOCK 29-11-00/201).
IAW AMM TASK 78-31-20-024-001-R04 2.F.1
2 Make sure that the forward thrust lever is in the idle position and that the reverse thrust lever is
fully forward. Attach the DO NOT OPERATE tags to both levers
IAW AMM TASK 78-31-20-024-001-R04 2.F.2
3 Open circuit breakers and install safety tags IAW AMM TASK 78-31-20-024-001-R04 2.F.3

WARNING: DO THE DEACTIVATION PROCEDURE FOR THE THRUST REVERSER

TO PREVENT THE OPERATION OF THE THRUST REVERSER. ACCIDENTAL
OPERATION OF THE THRUST REVERSER CAN CAUSE INJURIES TO PERSONS OR
DAMAGE TO EQUIPMENT.
4 Do the deactivation procedure for the thrust reverser for ground maintenance
(PAGEBLOCK 78-31-00/201 Config 4).
IAW AMM TASK 78-31-20-024-001-R04 2.F.4
5 Remove the hinge access door (PAGEBLOCK 78-31-10/401) IAW AMM TASK 78-31-20-024-
001-R04 2.F.5
NOTE: If the hinge access door hinges are not removed, tape must be applied to the plates in
the vertical position. The hinge and latch must not touch when the thrust reverser is opened.
6 Disconnect the hinges from the hinge access door IAW AMM TASK 78-31-20-024-001-R04
2.F.6

Form No: 757-78-30-01 Issue 1 - Dec2016 - Page 1 of 7

ITE REQUIREMENT MECH INSP
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7 Do an inspection of the C-duct lower attachment hoist point nut plates IAW AMM TASK 78-31-
20-024-001-R04 2.F.7
WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO OPEN THE
THRUST
REVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TO
PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.
8 Open the thrust reverser (PAGEBLOCK 78-31-00/201 Config 4) IAW AMM TASK 78-31-20-
024-001-R04 2.F.8
9 Do a Check of the load that is required to open the latched on the rear latch access panel IAW
AMM TASK 78-31-20-024-001-R04 2.F.9

10 Install the Floating Beam GSE pins to attach the floating Beam to the strut bracket when the thrust
reverser is removed IAW AMM TASK 78-31-20-024-001-R04 2.F.10
WARNING: THE HYDRAULIC FLUID CONTAINED IN THIS SYSTEM CAN CAUSE
INJURY TO YOU. IT IS POISONOUS WHEN IT IS ABSORBED INTO THE SKIN AND
WHEN IT PASSES THROUGH THE BODY. IN CASE THE FLUID TOUCHES THE
EYE, FLUSH THE EYES WITH WATER AND GET MEDICAL HELP.
CAUTION: THE HYDRAULIC FLUID WILL CAUSE DAMAGE TO AIRCRAFT
SURFACES WHERE THE HYDRAULIC FLUID DOES NOT USUALLY TOUCH.
REMOVE ANY FLUID WHICH HAS LEAKED IMMEDIATELY WITH A DRY CLOTH.
WASH THE AREA TO REMOVE THE CONTAMINATION.
11 Do the steps to disconnect the thrust reverser from all other systems IAW AMM TASK 78-31-20-
024-001-R04 2.F.11
CAUTION: MAKE SURE THE LOCKING PIN IS REMOVED FROM THE MANUAL
BYPASS VALVE BEFORE YOU DRAIN THE HYDRAULIC SYSTEM OF THE THRUST
REVERSER. IF THE LOCKING PIN IS NOT REMOVED, THE HYDRAULIC SYSTEM
OF THE AIRPLANE WILL DRAIN.

WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO CLOSE THE

THRUST REVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TO
PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR.
12
Close, but do not latch, the thrust reverser (PAGEBLOCK 78-31-00/201 Config 4) IAW AMM
TASK 78-31-20-024-001-R04 2.F.12
13 Install the 'c' duct hold open equipment IAW AMM TASK 78-31-20-024-001-R04 2.F.13
WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO OPEN THE
THRUST
REVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TO PERSONS
AND DAMAGE TO EQUIPMENT CAN OCCUR.
14 Open the thrust reverser (PAGEBLOCK 78-31-00/201 Config 4) IAW AMM TASK 78-31-20-
024-001-R04 2.F.14
15 Attach the fishpole hoist to the support assembly IAW AMM TASK 78-31-20-024-001-R04
2.F.15
16 Attach the strap to the fishpole hoist, and the bottom of the thrust reverser at two locations IAW
AMM TASK 78-31-20-024-001-R04 2.F.16

NOTE: Use the four bolts which are kept with the strap attach fittings.

WARNING: DO A TEST OF THE HOLD OPEN EQUIPMENT. MAKE SURE THE

HOLD OPEN EQUIPMENT CAN SUPPORT THE THRUST REVERSER BEFORE YOU
REMOVE THE HOLD OPEN RODS. IF YOU DO NOT DO A TEST OF THE HOLD
OPEN
EQUIPMENT, THE THRUST REVERSER COULD CLOSE SUDDENLY. THIS COULD
CAUSE INJURY TO YOU AND DAMAGE TO EQUIPMENT.
17 Use the fishpole hoist to lift the thrust reverser with an upward force equal to the weight of the
thrust reverser IAW AMM TASK 78-31-20-024-001-R04 2.F.17

NOTE: The left thrust reverser weighs approximately 670 lb (303.9 kg). The right thrust
reverser weighs approximately 660 lb (299.4 kg).

Form No: 757-78-30-01 – Issue 1 – Dec 2016 - Page 2 of 7

ITE REQUIREMENT MECH INSP
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18 Use the fishpole hoist to close the thrust reverser IAW AMM TASK 78-31-20-024-001-R04
2.F.18
19 Remove the strap from the bottom of the thrust reverser and from the fishpole hoist IAW AMM
TASK 78-31-20-024-001-R04 2.F.19
20 Remove the fishpole hoist from the support assembly IAW AMM TASK 78-31-20-024-001-R04
2.F.20
21 Remove the support assembly (part of 'c' duct hold open equipment) from the arch IAW AMM
TASK 78-31-20-024-001-R04 2.F.21
22 Do the steps to install the available handling equipment on the thrust reverser IAW AMM TASK
78-31-20-024-001-R04 2.F.22
NOTE: When the inboard thrust reverser is removed or installed, attach a belt inboard c-
duct sling, SPL-10511 to the installation frame. This is necessary so that the leading edge of
the wing is not damaged.
Attach the inboard c-duct sling, SPL-10511 to the hole which is found on the handling frame.
Make sure there is a 10° angle between the reverser and the engine.
23 Remove the thrust reverser IAW AMM TASK 78-31-20-024-001-R04 2.F.23

NOTE: The left thrust reverser weighs approximately 670 lb (303.9 kg). The right thrust
reverser weighs approximately 660 lb (299.4 kg).

WARNING: DO NOT STAND UNDER OR NEAR THE THRUST REVERSER WHEN

THE
THRUST REVERSER IS LIFTED. PERSONS COULD BE INJURED IF THE THRUST
REVERSER FALLS OR MOVES LATERALLY.
CAUTION: CONTROL MOVEMENT OF THE THRUST REVERSER WITH TAG
LINES.
MOVE THE THRUST REVERSER CAREFULLY TO MAKE SURE THE THRUST
REVERSER DOES NOT HIT THE STRUT, ENGINE, OR GROUND EQUIPMENT.

THRUST REVERSER INSTALLATION

ITE REQUIREMENT MECH INSP

M
24 Verify that the cascade vane configuration of the on-going thrust reverser is correct for the
position that it is to be installed
25 Perform external general visual inspection of the zones with thrust reverser removed per MPD
task 71-804-50 or 71-808-50 before installation of the thrust reverser.
26 Remove the screws and remove the actuator access panel IAW AMM TASK 78-31-20-424-028-
R04 3.I.1
27 If installed, remove the side access panel IAW AMM TASK 78-31-20-424-028-R04 3.I.2

28 Make sure the hinges of the hinge access door are attached in the vertical position IAW AMM
TASK 78-31-20-424-028-R04 3.I.3
29 Make sure the opening actuator is retracted IAW AMM TASK 78-31-20-424-028-R04 3.I.4

30 Apply silicone grease to all the open closing seals, the engine mating faces and the V-groove
system IAW AMM TASK 78-31-20-424-028-R04 3.I.5.
31 Release the lower feedback cable rodend from the feedback actuation lever IAW AMM TASK 78-
31-20-424-028-R04 3.I.6
NOTE: Do a check of the bolt which attaches the feedback rod end. If it is attached with the
bolt head rearward, it will be necessary to manually retract the thrust reverser.
Retract the thrust reverser approximately 4.0 inches (101.6 mm) so that the bolt can be
removed (PAGEBLOCK 78-31-00/201 Config 4).

Form No: 757-78-30-01 – Issue 1 – Dec 2016 - Page 3 of 7

ITE REQUIREMENT MECH INSP
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32 Install the Rolls Royce handling equipment, if available IAW AMM TASK 78-31-20-424-028-
R04 3.I.7
NOTE: When the inboard thrust reverser is removed or installed, attach a belt inboard c-
duct sling, to the installation frame. This is necessary so that the leading edge of the wing is
not damaged. Attach the belt sling to the hole which is found on the handling frame. Make
sure there is a 10° angle between the thrust reverser and the engine.

NOTE: The left thrust reverser weighs approximately 670 lbs (303.91 kg). The right thrust
reverser weighs approximately 660 lbs (299.67 kg).
33 Install the Boeing handling equipment, if available IAW AMM TASK 78-31-20-424-028-R04
3.I.8 and IAW AMM TASK 78-31-20-424-028-R04 3.I.9

34 Install the thrust reverser IAW AMM TASK 78-31-20-424-028-R04 3.I.10

WARNING: MAKE SURE ALL THE WEIGHT OF THE THRUST REVERSER IS HELD
BY THE 'c' duct hold open equipment. DO NOT STAND BETWEEN THE THRUST
REVERSER AND THE ENGINE. THE THRUST REVERSER COULD CLOSE
SUDDENLY AND INJURE PERSONS.

CAUTION: MAKE SURE TO CHECK THE RUN-ON TORQUE OF THE THRUST

REVERSER HINGE BOLTS. MAKE SURE THE NUT IS TORQUED PROPERLY TO
KEEP THE BOLT AND/OR BUSHING FROM BECOMING LOOSE AND MIGRATING.
CAUTION: YOU MUST MAKE SURE THE LINK IS CORRECTLY POSITIONED
BEFORE AND DURING INSTALLATION OF THE THRUST REVERSER. IF THE LINK
IS NOT CORRECTLY POSITIONED, DAMAGE TO THE C-DUCT AND THRUST
REVERSER CAN OCCUR.

Install the washer and the nut to the aft hinge bolt.

Record Torque Value______________

Torque Wrench P/N_______________

Torque Wrench S/N_______________

Torque Wrench Calibration Date ____________

Install the nuts on the centre and forward hinge bolts.

Record Torque Value______________

Torque Wrench P/N_______________

Torque Wrench S/N_______________

Torque Wrench Calibration Date ____________

CAUTION: YOU MUST MAKE SURE THE LINK IS CORRECTLY POSITIONED

BEFORE AND DURING INSTALLATION OF THE THRUST REVERSER. IF THE LINK
IS NOT CORRECTLY POSITIONED, DAMAGE TO THE C-DUCT AND THRUST
REVERSER CAN OCCUR.
35 Remove the handling equipment IAW AMM TASK 78-31-20-424-028-R04 3.I.11

36 Attach the support assembly to the arch IAW AMM TASK 78-31-20-424-028-R04 3.I.12

37 Attach the fishpole hoist (2 preferred) to the support assembly IAW AMM TASK 78-31-20-424-
028-R04 3.I.13
38 Attach the sling to the brackets which are found on the bottom of the thrust reverser IAW AMM
TASK 78-31-20-424-028-R04 3.I.14.

Form No: 757-78-30-01 – Issue 1 – Dec 2016 - Page 4 of 7

ITE REQUIREMENT MECH INSP
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39 Attach the sling to the fishpole hoist IAW AMM TASK 78-31-20-424-028-R04 3.I.15

40 Use the fishpole hoist to open the thrust reverser IAW AMM TASK 78-31-20-424-028-R04 3.I.16

41 Install the hold open rods IAW AMM TASK 78-31-20-424-028-R04 3.I.17

42 Make sure the translating sleeve is in the fully retracted position IAW AMM TASK 78-31-20-
424-028-R04 3.I.18:

DO NOT APPLY A TORQUE WHICH IS MORE THAN THE MAXIMUM CRANK

TORQUE. DAMAGE TO THE ACTUATOR COULD RESULT. THE DRIVE MUST BE
INSTALLED CORRECTLY. IF THE DRIVE IS NOT INSTALLED CORRECTLY,
SIDE LOADING COULD DAMAGE THE ACTUATOR.
43 Open the strut pressure relief door (PAGEBLOCK 54-53-01/401 Config 1, Figure 413) IAW
AMM TASK 78-31-20-424-028-R04 3.I.19.

44 Turn the feedback cam to the retracted position and install the rig pin in rig pin set IAW AMM
TASK 78-31-20-424-028-R04 3.I.20

45 Align the lower feedback cable rodend with the actuation lever IAW AMM TASK 78-31-20-424-
028-R04 3.I.21.
NOTE: If the cable rod end does not align, loosen the locknut and adjust the rod end as
necessary.
Apply a light load to remove the slack in the feedback cable.
46 Install the lower cable rodend in the actuation lever with the bolt, the washer, and the nut. Install a
new cotter pin IAW AMM TASK 78-31-20-424-028-R04 3.I.22.

Record Torque Value______________

Torque Wrench P/N_______________

Torque Wrench S/N_______________

Torque Wrench Calibration Date ____________

47 Tighten the locknut of the lower feedback cable using AMM torque values IAW AMM TASK 78-
31-20-424-028-R04 3.I.23

Record Torque Value______________

Torque Wrench P/N_______________

Torque Wrench S/N_______________

Torque Wrench Calibration Date ____________

48 Remove the rig pin from the feedback cam and close the strut pressure relief door IAW AMM
TASK 78-31-20-424-028-R04 3.I.24

WARNING: MAKE SURE THE THRUST REVERSER IS HELD BY THE HOLD-OPEN

RODS. IF THE HOLD OPEN RODS DO NOT HOLD THE THRUST REVERSERS, THE
THRUST REVERSER COULD CLOSE SUDDENLY WHEN THE HOIST IS REMOVED.
THIS COULD CAUSE INJURY TO PERSONS.
49 Release some of the load on the fishpole hoist IAW AMM TASK 78-31-20-424-028-R04 3.I.25.
Let the hold-open rods hold some of the weight of the thrust reverser.
50 Connect the hand pump to the thrust reverser IAW AMM TASK 78-31-20-424-028-R04 3.I.26.

Form No: 757-78-30-01 – Issue 1 – Dec 2016 - Page 5 of 7

ITE REQUIREMENT MECH INSP
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51 Use the hand pump to slowly extend the actuator rod end to the strut clevis. (PAGEBLOCK 70-
51-00/201, Figure 406) IAW AMM TASK 78-31-20-424-028-R04 3.I.27

52 Install the bolt, the bushing, and the nut which attaches the actuator rod end to the strut clevis
IAW AMM TASK 78-31-20-424-028-R04 3.I.28
53 Remove the GSE Pins from the Floating Beam IAW AMM TASK 78-31-20-424-028-R04 3.I.29.

54 Connect the airplane systems IAW AMM TASK 78-31-20-424-028-R04 3.I.30

1) To make sure the tubenut does not rotate, hold the bulkhead adapter with an open-end wrench.
2) Tighten the tubenut (PAGEBLOCK 70-51-00/201).
55 Do the steps to do the thrust reverser synchronization procedure. IAW AMM TASK 78-31-20-
424-028-R04 3.I.31
NOTE: Thrust reverser synchronization is not necessary if the replacement thrust reverser
was hydraulically retracted in the shop. These thrust reversers should be identified with a
label. It is also not necessary if the thrust reverser was hydraulically retracted on the wing
and was not opened. Also, the remaining thrust reverser half must operate correctly and be
hydraulically retracted. If these conditions do not occur, then the synchronizing procedure
must be done.
CAUTION: MAKE SURE THE THRUST REVERSER IS ADJUSTED CORRECTLY. IF
THE THRUST REVERSER IS NOT ADJUSTED CORRECTLY, THE ACTUATION
SYSTEM OF THE THRUST REVERSER COULD BE DAMAGED.

(p-6) Tighten the connector ref AMM torque limits,

Record Torque Value______________

Torque Wrench P/N_______________

Torque Wrench S/N_______________

Torque Wrench Calibration Date ____________

56 If the thrust reverser synchronization procedure was not done, connect the flex synchronizing shaft
which connects the extend hydraulic tube IAW AMM TASK 78-31-20-424-028-R04 3.I.32.
NOTE: Do not bend the flex shaft more than 22.5 degrees.

Tighten the connector per AMM

Record Torque Value______________

Torque Wrench P/N_______________

Torque Wrench S/N_______________

Torque Wrench Calibration Date ____________

57 BRI ALL POST SB RB211-78-9017

Put the sleeve assembly, the restraint bracket, the new seal, and the split support clamp on the
firewall IAW AMM TASK 78-31-20-424-028-R04 3.I.34.
NOTE: Restraint bracket is installed on right side only.
58 Install the side access panel IAW AMM TASK 78-31-20-424-028-R04 3.I.35.

59 Do a check of the bellows of the pre-cooler fan air intake for damage IAW AMM TASK 78-31-
20-424-028-R04 3.I.36.

60 Do a check of the bellow seals for damage IAW AMM TASK 78-31-20-424-028-R04 3.I.37.

61 Open the valve on the hand pump IAW AMM TASK 78-31-20-424-028-R04 3.I.38.

Form No: 757-78-30-01 – Issue 1 – Dec 2016 - Page 6 of 7

ITE REQUIREMENT MECH INSP
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62 Use the fishpole hoist to lift the thrust reverser with a force equal to its weight IAW AMM TASK
78-31-20-424-028-R04 3.I.39

63 Disconnect the hold open rods IAW AMM TASK 78-31-20-424-028-R04 3.I.40

64 Use a fishpole hoist to lower the thrust reverser to the closed position IAW AMM TASK 78-31-
20-424-028-R04 3.I.41.

65 Remove the sling from the bottom of the thrust reverser and from the fishpole hoist IAW AMM
TASK 78-31-20-424-028-R04 3.I.42

66 CAUTION: THE STEP THAT FOLLOWS MUST BE DONE TO MAKE SURE THAT
ALL THE AIR WHICH REMAINS IN THE HYDRAULIC SYSTEM IS BLED. IF YOU
DO NOT, AIR WHICH REMAINS IN THE SYSTEM CAN CAUSE THE THRUST
REVERSER TO CLOSE IRREGULARLY.
Bleed the hydraulic opening system of the thrust reverser IAW AMM TASK 78-31-20-424-028-
R04 3.I.43.

67 IAW AMM TASK 78-31-20-424-028-R04 3.I.44, Do this procedure: Thrust Reverser Lock
Proximity Sensor - Adjustment/Test (PAGEBLOCK 78-30-00/501 Config 4)
WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO CLOSE THE
THRUST REVERSERS. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TO
PERSONS AND DAMAGE TO EQUIPMENT CAN OCCUR
68 IAW AMM TASK 78-31-20-424-028-R04 3.I.45, Close the access panels: (PAGEBLOCK 78-31-
00/201 Config 4)

69 Remove the support assembly, the braces, the arch assembly, the two pads, and the two front
brackets IAW AMM TASK 78-31-20-424-028-R04 3.I.46
70 IAW AMM TASK 78-31-20-424-028-R04 3.I.47, Do this procedure: Thrust Reverser Upper and
Lower Bifurcation Bumper and Latch Adjustment (PAGEBLOCK 78-30-00/501 Config 4).
71 Attach the hinge access door hinges to the thrust reverser IAW AMM TASK 78-31-20-424-028-
R04 3.I.48
72 IAW AMM TASK 78-31-20-424-028-R04 3.I.49, Install the hinge access door (PAGEBLOCK
78-31-10/401).
73 IAW AMM TASK 78-31-20-424-028-R04 3.I.50, Pressurize the hydraulic system (PAGEBLOCK
29-11-00/201).

74 Bleed the hydraulic system of the thrust reverser IAW AMM TASK 78-31-20-424-028-R04
3.I.51.
NOTE: This procedure will make sure all the unwanted air is bled from the system. If the
air is not bled from the system, the thrust reverser may not operate satisfactorily.
75 Remove the DO NOT OPERATE tags from the thrust reverser levers IAW AMM TASK 78-31-
20-424-028-R04 3.I.52.

76 IAW AMM TASK 78-31-20-424-028-R04 3.I.53, Do the thrust reverser tests that are listed in the
test reference table (PAGEBLOCK 78-31-00/501 Config 1).
77 Do a check of all the hydraulic connections which have been opened to look for leakage IAW
AMM TASK 78-31-20-424-028-R04 3.I.54.

78 IAW AMM TASK 78-31-20-424-028-R04 3.I.55, Do a check of the adjustment of the upper and
lower bifurcation bumpers and latches (PAGEBLOCK 78-30-00/501 Config 4).
79 After the first engine ground run(s) and no later than 25 flight hours, do the IAW AMM TASK 78-
31-20-424-028-R04 3.I.56 to make sure the force necessary to close the five thrust reverser latches
is satisfactory and that the distance between the upper and lower bifurcation bumpers is
satisfactory.

PRINT NAME: SIGNATURE:

Form No: 757-78-30-01 – Issue 1 – Dec 2016 - Page 7 of 7

DATE: STAMP:

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