ADAMS RITE AEROSPACE

CAGE CODE: 80477

4141 NORTH PALM STREET
FULLERTON, CALIFORNIA 92835, U.S.A.
TEL: (714) 278-6500; FAX: (714) 278-6515

COCKPIT SYSTEM CONTROLLER

(USED ON AIRBUS AIRCRAFT A340-500/600 and A380)

AR4757-1 :(A340-500/600)
AR4757-3 :(A380)
AR4757-5 :(A340-500/600)

ABBREVIATED COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST

THIS DOCUMENT CONTAINS CONFIDENTIAL TECHNICAL DATA, INCLUDING TRADE SECRETS, PROPRIETARY TO ADAMS
RITE AEROSPACE, AND IS SUBMITTED UNDER A CONFIDENTIAL RELATIONSHIP. EXCEPT FOR USES EXPRESSLY
GRANTED IN WRITING, ALL RIGHTS ARE RESERVED BY ADAMS RITE AEROSPACE.

25-20-30
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Initial Release: Jun 22/04
REV 5. JUN 09/09
 ADAMS RITE AEROSPACE
ABBREVIATED
COMPONENT
MAINTENANCE MANUAL
AR4757

HIGHLIGHTS

TO: HOLDERS OF ADAMS RITE AEROSPACE ACMM 25-20-30 FOR COCKPIT CONTROL SYSTEM
AR4757-1/-3/-5, DATED FEB 14/08.

REVISION NO. 5 DATED JUN 09/09

Please discard old manual dated Feb 14/08 and replace it with this new manual
dated Jun 09/09.

Page No. Description of Change Effectivity

1 Changed to reflect this revision.
2 Changed to reflect this revision.
7 Deleted testing steps (3)(c) 4 and 5.

LIST OF REVISIONS

Rev. No. 1 2 3 4 5 6 7
Rev. Date Jun 22/04 Oct 25/04 Nov 02/06 Feb 14/08 Jun 09/09

LIST OF EFFECTIVE PAGES

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1. Description and Operation

NOTE: The Cockpit System Controller, P/N AR4757-1, 3, and -5, is a not field repairable
item for safety reasons.

The Cockpit Door Locking System (CDLS) Controller, P/N AR4757-1, 3, and 5, is an electronic
device installed in the aircraft that interfaces with noise-reduced solenoid controlled strike
mechanisms on commercial aircraft. It allows the flight crew control of the door lock system and
responds automatically to decompression events by releasing the door strike to prevent structural
damage to the aircraft. It is used in conjunction with the keypad and provides a method for
authorized personnel to gain access to the flight deck.

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ABBREVIATED
COMPONENT
MAINTENANCE MANUAL
AR4757

The Controller is comprised of a small metallic enclosure containing pressure sensors and
electronics. The controller interfaces with a keypad, strikes and with aircraft systems via
connectors mounted on the controller enclosure.

The CDLS unit is intended to be installed inside the (pressurized) flight deck and/or crew rest
areas of various aircraft models.

AR4757-3 is the same as AR4757-1 except that AR4753-3 has an EMI improved case. Also,
outputs for emergency and routine access have been separated.

NOTE: AR4757-1 and AR4757-3 are not interchangeable.

The difference in functionality between AR4757-1 and AR4757-5 is that the AR4757-5 has a
software modification that prevents the fault light and the three solenoid indicator lights from
illuminating during an emergency opening sequence. All other aspects of functionality are
identical.

The physical difference between the AR4757-1 and the AR4757-5 is that the AR4757-5 connects
to a single strike. Also, the waiting time or time-out after entering the emergency code is set to
“0,” so there is no waiting time to open the door.

NOTE: AR4757-5 is a part number created due to a specific operator request for purposes
outside the cockpit door reinforcement program. AR4757-5 is used for crew
rest/crew compartments. Incapacitation code rather than the normal entry code is
used for normal rest/crew compartment entry.
CONNECTOR A
B21FE26PW-T02
MATES WITH
E0052( )16B26SW
CONNECTOR B
B21FC10PW-T01
MATES WITH
E0052( )12B10SW

EMI FINGER
STRIP
2 PLACES

FIGURE 1. CONTROLLER CONNECTIONS

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MAINTENANCE MANUAL
AR4757

A. Approximate Dimensions and Weights

Length: 147.066 mm ± .508 mm (5.790 in ± .020 in)

Width: 145.999 mm ± .254 mm (5.748 in ± .010 in)
Height: 46.838 mm ± .254 mm (1.844 in ± .010 in)
Weight 1.29 Kg (2.85 lb)

2. Testing and Fault Isolation (Refer to Figure 1 and 2)

A. General

To properly test the system, the Controller must be either 1.) connected to a complete
system for proper testing, 2.) connected to ARA Test Fixture TF-126, or 3.) tested on
aircraft. The system is shown in Figure 2.

NOTE: Make sure you set the mode switch for -1 or -3 configurations as is appropriate.
The -5 configuration systems should be tested with switch in -1 position.

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COMPONENT
MAINTENANCE MANUAL
AR4757

NOTE: Wire bundles TF-127

and TF-128 required to
complete system

TF-127 TF-128

AR4710-3 AR4756-1 AR4756-3 AR4756-1

KEYPAD UPPER CENTER BOTTOM

NORMAL NORMAL NORMAL

FAIL UP FAIL UP FAIL UP

FAIL DN FAIL DN FAIL DN

AR4757-1 NORMAL ENTRY

AR4757-3 EMERGENCY ENTRY

DOOR OPEN
DOOR OPEN

UNLOCK LOCK FAULT

POWER
AR4757-1 LAMP TEST AUDIO ALERT
SUPPLY
CONTROL UNIT

UPPER CENTER LOWER

MAIN

TEST FIXTURE TF126

NOTE: Test Fixture TF-126 shown
for illustration purposes only.
When connected, orientation
will be different.

FIGURE 2. SYSTEM DEPICTION

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MAINTENANCE MANUAL
AR4757

B. Procedure

(1) System Power ON

(a) All three solenoids should energize.

(b) If all three pins do NOT energize:

1 Verify power to the Controller.

2 Check connections.

3 If connections are correct, the Controller is defective.

(2) Unlock Feature

(a) Activate Unlock switch/button.

1 While the unlock switch/button is activated, all three pins should

de-energize.

2 After releasing the unlock switch/button, all three pins should

energize within approximately ½ second.

3 If pins do NOT energize.

a Check connections.

b If connections are correct, the Controller is defective.

(3) Request Access Feature – Accept

(a) Enter the “normal entry code” on keypad.

(b) “Audio Alert” lamp should illuminate on aircraft or test fixture TF126. If
“Audio Alert” lamp does NOT illuminate:

1 Activate “UNLOCK” switch/button.

2 Repeat step (5) (a).

3 If the “Audio Alert” lamp does not illuminate:

a Check connections.

b If connections are correct the default “normal entry code”

could have been changed.

c Contact your designated Airline CDLS Coordinator.

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AR4757

(c) If “Audio Alert” lamp illuminates, activate the “UNLOCK” switch/button

1 Green LED on keypad should turn “ON.”

2 All three strikes (catch release pins) should de-energize while

“unlock” switch/button is activated.

3 All three strikes (catch release pins) should re-energize within

approximately ½ second after the “unlock” switch/button is
released.

(4) Request Access Feature – Deny

(a) Enter the “normal entry code.”

(b) “Audio Alert” lamp should illuminate on aircraft or test fixture TF126.

(c) Activate “LOCK” switch/button on aircraft or test fixture TF126.

1 The Red LED on Keypad should turn ON

2 Enter the “normal entry code” on keypad. The “Audio Alert” light
should NOT illuminate on aircraft or Test Fixture TF126 (the
system default “lock time” is 5 minutes.).

3 If “Audio Alert” lamp illuminates, the Controller is defective.

(d) After the “lock time” duration has expired, enter “normal entry code” on
keypad. The “Audio Alert” lamp should illuminate in cockpit.

1 If the “Audio Alert” lamp does not illuminate, the Controller is

defective or needs to be re-programmed.

(5) Incapacitation (used as normal access for AR4757-5)

(a) Enter the “emergency entry code.”

(b) For -3 only, the “Emergency Entry” request lamp will illuminate.

(c) The green keypad LED should begin to flash.

1 If the green LED does NOT flash, the “emergency entry code” could
have been changed.

2 Verify code with your Designated Airline CDLS Coordinator.

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MAINTENANCE MANUAL
AR4757

3 The “Audio Alert” lamp should illuminate for 15 to 120 seconds

on aircraft or on TF126 (the system default for release is 30
seconds; 0 seconds for AR4757-5).

a If the “Audio Alert” lamp does NOT illuminate, the

Controller is defective.

b If the “Audio Alert” lamp illuminates less than 15 seconds

or greater than 120 seconds, the Controller is defective.

4 After the emergency delay time has expired, the three strikes
should de-energize for approximately 5 seconds. The strikes
should then energize.

(6) Decompression

(a) Use ARA Decompression Test Simulator, AR4728-1, to test the

decompression feature. Refer to Figure 3.

1 Push plunger into cylinder until it locks into place.

CAUTION: DO NOT PUSH NOZZLE INTO OPENING OF

COCKPIT CONTROLLER.

2 Hold rubber nozzle up to one opening on Cockpit Controller.

3 As Simulator is held up to opening, press release button on

Simulator.

4 All three strikes (release pins) should de-energize for

approximately 1 second. All three strikes (release pins) should
energize. Cockpit Controller lights should flash on then off.

5 Repeat Steps 1 thru 4 on the other Controller opening.

FIGURE 3. USE OF DECOMPRESSION TOOL, P/N AR4728-1

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ABBREVIATED
COMPONENT
MAINTENANCE MANUAL
AR4757

(7) DOOR OPEN LIGHT

(a) Push switch lever located inside catch center strike AR4756-3. The Door
Open Light should turn off when the lever is depressed. Verify strikes
per CMM 25-20-34.

(b) If the Door Open Light does not turn off and the strike is operational, the
Controller is defective.

3. Schematics and Wiring Diagrams

PIN-OUT TABLE – B21FC10PW-T01, CONNECTOR B (10 Pin)

Table 1

POS DESCRIPTION OF SIGNAL PIN

1 Data 0 (from Keypad) A
2 Data 1 (from Keypad) B
3 Data 2 (from Keypad) C
4 Data 3 (from Keypad) D
5 LED 1 (green) E
6 LED 2 (red) F
7 VCC for Keypad G
8 GND for Keypad K

PIN-OUT TABLE – B21FE26PW-T02, CONNECTOR A (26 Pin)

Table 2

POS DESCRIPTION OF SIGNAL PIN

1 UNLK A
2 LOCK B
3 Buzzer C
4 6.3 VDC GND D
5 Status Lower Locking Mechanism E
6 Access Requested (Video) F
7 Cockpit Indication FAULT G
8 Center Locking Mechanism – Limit Switch H
9 Cockpit Indication OPEN J
10 Lamp test K
11 DC GND L
12 Status Upper Locking Mechanism M
14 Status Center Locking Mechanism P
15 28 VDC R
16 Chassis GND S
17 Access Request (EMER) (-3 only) T
18 Lower Locking Mechanism – Hold Signal U
19 Lower Locking Mechanism – Vcc V
20 Lower Locking Mechanism – Push Signal W
21 Center Locking Mechanism - Push Signal X
22 Upper Locking Mechanism – Push Signal Y
23 Upper Locking Mechanism – Vcc Z

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MAINTENANCE MANUAL
AR4757

Table 2 (continued)

POS DESCRIPTION OF SIGNAL PIN

24 Upper Locking Mechanism – Hold Signal a
25 Center Locking Mechanism - Hold Signal b
26 Center Locking Mechanism - Vcc c

4. Disassembly

Not applicable.

5. Cleaning

CAUTION: EXCESSIVE LIQUID COULD CAUSE DAMAGE TO UNIT.

Use damp cloth with mild detergent (without an excessive amount of water).

6. Inspection/Check

Not applicable.

7. Repair

Not applicable.

8. Assembly

Not applicable.

9. Fits and Clearances

Not applicable.

10. Special Tools, Fixtures, Equipment and Consumable Materials

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

Table 3

SUPPLIERS CODE OR NAME

PART NO. DESCRIPTION
AND ADDRESS
TF126 Test Fixture ARA (80477)
TF127 Wire Bundle for Testing ARA (80477)
TF128 Wire Bundle for Testing ARA (80477)
AR4728-1 Decompression Simulator ARA (80477)

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COMPONENT
MAINTENANCE MANUAL
AR4757

11. Illustrated Parts List

AR4757-1/-3 SHOWN

AR4757-5 SHOWN

UNITS
AIRLINE
FIG. EFF PER
PART NO.
ITEM PART NO. 1234567 NOMENCLATURE Code ASSY

1 -1 AR4757-1 COCKPIT SYSTEM CONTROLLER ASSY RF

R -1A AR4757-3 COCKPIT SYSTEM CONTROLLER ASSY RF
R -1B AR4757-5 COCKPIT SYSTEM CONTROLLER ASSY RF
-ITEM NOT ILLUSTRATED

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MAINTENANCE MANUAL
AR4757

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