CMM 21-25 Linear Actuator

TO: HOLDERS OF LINEAR ACTUATOR ASSEMBLY SYLC 51836 SERIES COMPONENT
MAINTENANCE MANUALS
REVISION NO. 2 DATED FEBRUARY 18/2004
HIGHLIGHTS
This is Revision 2 for the SYLC 51836 Component Maintenance Manual.
Pages which have been added or revised are outlined below together with the highlights of the revision. On
the pages affected by Revision 1, change bars are included only for Revision 2 changes. Remove and insert
the affected pages as listed and verify that Revision No. 2 dated Feb 18/2004 has been added to the Record
of Revisions sheet.
Chapter/Section
and Page No. Description of Change Effectivity
Title Revised to show latest revision. All Models
Record of Revised to include Revision 2 information. All Models

Revisions
List of Effective Revised to indicate revised pages. All Models

Page 1
Testing and Revised Figure 109 All Models

Troubleshooting
112
Repair Revised Figure 603 All Models
607
Highlights
21-25-03 Page 1
Feb 18/2004
FOR EUROPE, AFRICA, INDIA FOR ASIA, AUSTRALASIA AND THE FOR THE AMERICAS
AND MIDDLE EAST CONTACT: PACIFIC CONTACT: CONTACT:
Smiths Aerospace Smiths Aerospace Australia Pty Ltd Smiths Aerospace
Customer Services - Heathrow Casuarina Street P.O. Box 9013, Clearwater, FL 33758
Bishops Cleeve, Cheltenham, Brisbane Airport, QLD4007 United States of America
Glos, GL52 8SF, United Kingdom Australia
Telephone: + 44 (0) 1242 673355 Telephone: + 61 7 3860 0700 Telephone: + 1 (727) 539 1631
Facsimile: + 44 (0) 1242 669163 Facsimile: + 61 7 3860 0701 Facsimile: + 1 (727) 539 0680
E-Mail: CS.support@smiths-aerospace.com E-Mail: admin@smithsind.com.au E-Mail: CSAsupport@smiths-aerospace.com

www.smiths-aerospace.com
COMPONENT MAINTENANCE MANUAL

WITH ILLUSTRATED PARTS LIST
LINEAR ACTUATOR
PART NUMBER
SYLC51836
SYLC51836-1
SYLC51836-10
Uncontrolled when reproduced 21-25-03

SMITHS AEROSPACE TITLE PAGE
ROCKFORD REVISION 2 FEBRUARY 18/2004
SYLC51836 SERIES
SAFETY ADVISORY
This publication describes physical and chemical processes which may require the use of chemicals,
solvents, paints or other commercially available materials.
The user of this publication should obtain the material safety data sheets (Occupational Safety and Health Act
(OSHA) Form 20 or equivalent) from the manufacturers/suppliers of materials to be used. The user must
become completely familiar with the manufacturer/supplier information and adhere to the procedures,
recommendations, warnings and cautions of the manufacturer/supplier for the safe use, handling, storage,
and disposal of these materials.
WARNING: BEFORE YOU USE ANY OF THE MATERIALS SPECIFIED IN THIS MANUAL, BE AWARE
OF ALL HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE
MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH MANUFACTURER'S OR
SUPPLIER'S RECOMMENDATIONS MAY RESULT IN PERSONAL INJURY OR DISEASE.
See the materials list figure at the beginning of each section of this manual for materials used in the
maintenance of this equipment.
WARNINGS are provided to alert operating and maintenance personnel to potential hazards that could result
in personal injury; they do not replace the manufacturer's recommendations.
CAUTIONS are provided to alert operating and maintenance personnel to conditions that could result in
equipment damage.
This Safety Advisory contains the WARNINGS and CAUTIONS included in the manual and they are
presented here to bring your attention to their existence and to highlight their importance.
WARNING: PERFORM SOLVENT CLEANING IN AN APPROVED CLEANING CABINET OR IN A WELL-

VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS. AVOID EYE AND
REPEATED SKIN CONTACT. KEEP SOLVENTS AWAY FROM SPARKS, FLAMES, AND
OTHER IGNITION SOURCES.
WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE
IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT SURFACES. WEAR
SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES AND OTHER PROTECTIVE GEAR.
IN CASE OF EYE OR SKIN CONTACT, FLUSH WITH WATER AND SEEK MEDICAL
ATTENTION.
WARNING: COMPRESSED AIR USED FOR CLEANING OR DRYING CAN CREATE AIRBORNE
PARTICLES THAT MAY ENTER THE EYES. PRESSURE MUST NOT EXCEED 30 PSIG
(206,8 KPA) AND THEN ONLY WITH EFFECTIVE CHIP GUARDING AND PERSONAL
PROTECTIVE EQUIPMENT. DO NOT DIRECT COMPRESSED AIR TOWARD YOURSELF
OR ANYONE ELSE.
Safety Advisory
Page 1
21-25-03 Sep 14/01
SYLC51836 SERIES
WARNING: EPOXY ADHESIVE IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND
SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH
WITH WATER AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH
WITH SOAP AND WATER.
WARNING: SILICONE ADHESIVE SEALANT IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT

EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE
CONTACT, FLUSH WITH WATER AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN
CONTACT, WASH WITH SOAP AND WATER.
WARNING: THERMAL STRIPPERS SHOULD BE USED ONLY IN WELL-VENTILATED AREAS TO

PROTECT PERSONNEL AGAINST TOXIC FUMES GENERATED BY INSULATING
MATERIALS SUCH AS POLYTETRAFLUOROETHYLENE (TEFLON) OR
POLYVINYLCHLORIDE.
WARNING: DO NOT APPLY POWER TO THE UNIT OR TEST FIXTURE WHILE YOU CONNECT THE
TEST SETUP.
WARNING: BEFORE ATTEMPTING ANY SOLDERING, PERSONNEL MUST BE FAMILIAR WITH

TYPICAL SOLDERING PROCEDURES FOR AIRPLANE ELECTRICAL AND ELECTRONIC
WIRING, INCLUDING WARNINGS AND CAUTIONS. WEAR EYE PROTECTION AND AVOID
BREATHING FUMES GENERATED BY SOLDERING OR SOLVENTS. TO AVOID
INGESTION OF POISONOUS LEAD OXIDE FROM SOLDER, PERSONNEL MUST WASH
HANDS BEFORE SMOKING OR EATING. EYE PROTECTION IS REQUIRED. USE
EXTREME CAUTION TO AVOID BEING BURNED.
WARNING: DS-108 SOLVENT IS TOXIC AND COMBUSTIBLE. DO NOT BREATHE VAPORS. USE IN A
WELL-VENTILATED AREA FREE FROM SPARKS, FLAME OR HOT SURFACES. WEAR
SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES AND OTHER PROTECTIVE GEAR.
IN CASE OF EYE CONTACT, FLUSH WITH WATER AND SEEK MEDICAL AID. IN CASE OF
SKIN CONTACT, WASH WITH SOAP AND WATER.
WARNING: ALODINE NO. 1200S (CHEMICAL CONVERSION COATING) IS TOXIC AND CORROSIVE
TO HUMAN TISSUE. WASH THE SKIN THOROUGHLY IF EXPOSURE OCCURS. IF
SOLUTION GETS IN THE EYES, FLUSH WITH WATER FOR 15 MINUTES AND SEEK
MEDICAL HELP IMMEDIATELY. USE IN A WELL-VENTILATED AREA. WEAR SPLASH
GOGGLES, SOLVENT-RESISTANT GLOVES AND OTHER PROTECTIVE GEAR. KEEP
ALODINE 1200S AWAY FROM ACIDS. RINSE APPLICATOR WITH WATER BEFORE
DISPOSAL. DO NOT ALLOW ORGANIC MATERIALS TO BECOME WET WITH ALODINE
1200S AS THEY WILL BECOME SERIOUS FIRE HAZARDS WHEN DRY. ALODINE 1200S
IS A FIRE HAZARD WHEN DRY.
CAUTION: DO NOT ALLOW CLEANING SOLVENT OF ANY KIND TO COME IN CONTACT WITH ANY
NYLON, RUBBER, OR ELECTRICAL PART.
CAUTION: HOLD END BODY ASSEMBLY WHEN LOOSENING/TIGHTENING JAM NUT TO PREVENT
DAMAGE TO THE MOVING TUBE ASSEMBLY.
Safety Advisory
Page 2
21-25-03 Sep 14/01
SYLC51836 SERIES
CAUTION: DO NOT ALLOW SILICONE ADHESIVE SEALANT TO CONTACT THE PREFORMED
PACKING OR THE MOVING TUBE ASSEMBLY WHEN SEALING THE COVER TO MOVING
TUBE HOUSING. THIS COULD INTERFERE WITH MOVEMENT OF THE MOVING TUBE
ASSEMBLY.
CAUTION: USE AN ISOLATED LOW-WATTAGE CONTROLLED HEAT SOLDERING IRON TO

PREVENT DAMAGING COMPONENTS DURING SOLDER REMOVAL.
CAUTION: UNPACKAGED STORAGE IS NOT RECOMMENDED.
CAUTION: LIGHTLY COAT THE GEAR ASSEMBLY TEETH WITH GREASE. EXCESS AMOUNTS OF
GREASE WILL BIND THE GEAR TRAIN.
CAUTION: USE CARE TO KEEP EPOXY ADHESIVE AWAY FROM MOTOR PINION. EPOXY
ADHESIVE CAN BIND MOTOR PINION AND CAUSE FAILURE OF MOTOR ASSEMBLY.
CAUTION: DISASSEMBLE THE LINEAR ACTUATOR ONLY AS FAR AS NECESSARY FOR REPAIR.
DISASSEMBLE ONLY AS FAR AS NECESSARY TO REMOVE AND REPLACE DAMAGED
COMPONENTS.
Safety Advisory
Page 3/4
21-25-03 Sep 14/01
SYLC51836 SERIES
RECORD OF REVISIONS
REV. ISSUE DATE DATE INSERTED REV. ISSUE DATE INSERTED

NO. INSERTED BY NO. DATE INSERTED BY
1 Jan 23, 2004 Jan 23, 2004 SKP
2 Feb 18, 2004 Feb 18, 2004 SKP
Record of Revisions
Page 1/2
21-25-03 Feb 18/2004
SYLC51836 SERIES
RECORD OF TEMPORARY REVISIONS
TEMPORARY PAGE ISSUE INSERTED DATE INSERTED

REV. NO. NUMBER DATE BY REMOVED BY
Record of Temporary Revisions

Page 1/2
21-25-03 Sep 14/01
SYLC51836 SERIES
SERVICE BULLETIN LIST
SERVICE DATE PARTS ADDED OR

BULLETIN NO. INCORPORATED DESCRIPTION CHANGED
Service Bulletin List

Page 1/2
21-25-03 Sep 14/01
SYLC51836 SERIES
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page 1 Jan 23/2004 Cleaning 401 Jan 23/2004

2 Blank 402 Sep 14/01
Safety Advisory 1 Sep 14/01 403 Sep 14/01
2 Sep 14/01 404 Blank
3 Sep 14/01 Check 501 Jan 23/2004
4 Blank 502 Sep 14/01
Record of Revisions 1 Jan 23/2004 Repair 601 Jan 23/2004
2 Blank 602 Jan 23/2004
Record of Temporary 1 Sep 14/01 603 Sep 14/01
Revisions 2 Blank 604 Sep 14/01
Service Bulletin List 1 Sep 14/01 605 Sep 14/01
2 Blank 606 Sep 14/01
List of Effective 1 Jan 23/2004 607 Feb 18/2004
Pages 2 Blank 608 Jan 23/2004
Table of Contents 1 Sep 14/01 Assembly 701 Jan 23/2004
2 Blank 702 Sep 14/01
Introduction 1 Sep 14/01 703 Jan 23/2004
2 Sep 14/01 704 Jan 23/2004
Description and 1 Sep 14/01 705 Jan 23/2004
Operation 2 Sep 14/01 706 Jan 23/2004
3 Sep 14/01 707 Sep 14/01
4 Blank 708 Blank
Testing and 101 Sep 14/01 Fits and Clearances 801 Sep 14/01
Fault Isolation 102 Jan 23/2004 802 Blank
103 Sep 14/01 Special Tools, Fixtures 901 Jan 23/2004
104 Sep 14/01 and Equipment 902 Jan 23/2004
105 Jan 23/2004 903 Sep 14/01
106 Jan 23/2004 904 Jan 23/2004
107 Sep 14/01 905 Jan 23/2004
108 Sep 14/01 906 Blank
109 Sep 14/01 Illustrated Parts List 1001 Sep 14/01
110 Sep 14/01 1002 Jan 23/2004
111 Jan 23/2004 1003 Sep 14/01
112 Feb 18/2004 1004 Blank
Automatic Test 201 Sep 14/01 1005 Sep 14/01
Requirements 202 Blank 1006 Sep 14/01
Disassembly 301 Jan 23/2004 1007 Jan 23/2004
302 Sep 14/01 1008 Sep 14/01
303 Jan 23/2004 1009 Jan 23/2004
304 Blank 1010 Jan 23/2004
List of Effective Pages

Page 1/2
21-25-03 Feb 18/2004
SYLC51836 SERIES
TABLE OF CONTENTS
SUBJECT PAGE
INTRODUCTION ................................................................................................................................................ 1
DESCRIPTION AND OPERATION .................................................................................................................... 1
TESTING AND FAULT ISOLATION .............................................................................................................. 101
AUTOMATIC TEST REQUIREMENTS .......................................................................................................... 201
DISASSEMBLY .............................................................................................................................................. 301
CLEANING ..................................................................................................................................................... 401
CHECK ........................................................................................................................................................... 501
REPAIR .......................................................................................................................................................... 601
ASSEMBLY .................................................................................................................................................... 701
FITS AND CLEARANCES ............................................................................................................................. 801
SPECIAL TOOLS, FIXTURES AND EQUIPMENT ........................................................................................ 901
ILLUSTRATED PARTS LIST ....................................................................................................................... 1001
Table of Contents
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21-25-03 Sep 14/01
SYLC51836 SERIES
INTRODUCTION
1. General.
Methods and procedures described in this publication are intended as a guide for the operation and
testing of the linear actuator assembly, Part Numbers SYLC51836, SYLC51836-1 and SYLC51836-10,
manufactured by:
Barber-Colman Aerospace was acquired by Smiths Aerospace. Our name is now Smiths Aerospace –
Rockford.
This Component Maintenance Manual has been revised/reissued by Smiths Aerospace – Rockford.
Refer to Smiths Aerospace – Rockford whenever a reference is made to either Smiths Aerospace,
Electronic Systems – Rockford or Barber-Colman Aerospace.
Smiths Aerospace - Rockford

1354 Clifford Avenue
P.O. Box 2909
Loves Park, Illinois 61132-2909
2. Layout of Manual.
This publication contains a general description and operation followed by data necessary for
maintenance, repair, disassembly, assembly, and testing of the linear actuator. This publication also
contains an Illustrated Parts List. Smiths Aerospace - Rockford Support Equipment/Tooling is defined by
part number prefixes of "NYLZ" or "PYLZ". Use the address listed above to order this equipment. For all
other equipment, please contact the manufacturer given as its source.
3. Revision Service.
This manual will be updated as required by revisions. Service Bulletins will be issued separately. Their
effect on the manual will be made evident by reissue of the Service Bulletin List.
4. List of Abbreviations.
The following abbreviations/symbols are used in this manual:
ABBREVIATION DEFINITION ABBREVIATION DEFINITION

Adc Amps Direct Current Corp. Corporation
ALT Alternate CT Connecticut
amp Amperes CW Clockwise
APU Auxiliary Power Unit DC Direct Current
AR As Required Dept. Department
ATA Air Transport Association Div. Division
Ave. Avenue DMM Digital Multimeter
AWG American Wire Gauge EMI Electromagnet Interference
BLK Black EXT Extend
Blvd. Boulevard FT Feet
BRN Brown Ft. Fort
CA California Hg Mercury
CCW Counterclockwise IL Illinois
Co. Company in. Inch
COM Common Inc. Incorporated
Introduction
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21-25-03 Sep 14/01
SYLC51836 SERIES
ABBREVIATION DEFINITION ABBREVIATION DEFINITION
IPL Illustrated Parts List OSHA Occupational Safety and Health Act
kg Kilogram PK. Park
KPA Kilopascals PM Permanent Magnet
lbs. Pounds psig Pounds per Square Inch Gage
lb in. Pound-Inches Rd. Road
M Meter RET Retract
MA Massachusetts RF Reference
mA Milliamperes SER Series
MI Michigan St. Street
MIL Military STD Standard
mm Millimeter TX Texas
min. Minimum Vac Volts alternating current
MS Military Standard Vdc Volts direct current
NC Normally Closed W. West
NH New Hampshire WA Washington
NJ New Jersey WHT White
Nm Newton Meter YEL Yellow
NO Normally Open % percent
No. Number ° degrees
NP Non-Procurable °F degrees Fahrenheit
NY New York °C degrees Celsius
ORN Orange Ω Ohms
Introduction
Page 2
21-25-03 Sep 14/01
SYLC51836 SERIES
DESCRIPTION AND OPERATION
1. General Information.
This section describes the purpose, description, and operation of the linear actuator assembly, Part
Numbers SYLC51836, SYLC51836-1, and SYLC51836-10.
2. Purpose.
The linear actuator assembly (Figure 1) is used to drive a bell crank and shaft that controls the APU
intake flapper valve position. It is used on the Embraer EMB 120, EMB 135 and EMB 145 aircraft.
3. Description.
A. The main components of the linear actuator are the motor assembly, connector and connector
block, reduction gear train, rear gear plate, jackscrew, moving tube assembly and moving tube
housing.
B. Two limit switches are provided to control actuator extension and retraction. The limit switches are
fitted with switch actuators that are actuated by adjustment screws located on the moving tube
assembly.
518361001.CDR
Linear Actuator
Figure 1
Description and Operation

Page 1
21-25-03 Sep 14/01
SYLC51836 SERIES
C. A position indicator switch is provided to give an indication when the linear actuator is in an
extended position. For SYLC51836-1, this switch uses gold contacts and has a maximum current
handling capacity of 10 mA.
D. Two low pass EMI filters are provided to filter out electrical noise and spikes from the applied
signals.
E. A connector block is provided for mounting the electrical connector. The electrical wiring for the
motor, limit switches, position switch and low pass EMI filters terminate at the connector.
F. The reduction gear train is housed in a rear gear plate. The gear train is driven by a pinion gear on
the motor shaft. The jackscrew has a gear that meshes with the reduction gear train. The reduction
gears are fitted with ball bearings. The jackscrew is fitted with two thrust bearings and a ball
bearing.
G. The inside diameter of the moving tube assembly has threads that mate with the threads on the
outside diameter of the jackscrew. Rotation of the jackscrew causes the moving tube assembly to
move along the length of the jackscrew.
4. Operation.
A. The moving tube extends as follows:
(1) Positive voltage is applied to connector pin A and neutral is applied to connector pin B. See
Figure 106 for the actuator schematic diagram.
(2) The moving tube extends out of the linear actuator until the adjustment screw on the moving
tube depresses switch S2, the extend limit switch. The switch opens and removes power to the
motor.
B. The moving tube retracts as follows:
(1) Positive voltage is applied to connector pin B and neutral is applied to connector pin A.
(2) The moving tube retracts into the linear actuator until the adjustment screw on the moving tube
depresses switch S1, the retract limit switch. The switch opens and removes power to the
motor.
C. The linear actuator uses switch S3, extend indicator, to control an electrical signal that indicates
when the linear actuator reaches the extended position.

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21-25-03 Sep 14/01
SYLC51836 SERIES
5. Leading Particulars.
Linear Actuator Specifications:

Width .................................................................................................................................. 1.05 in. (26,7 mm)
Height ................................................................................................................................. 1.93 in. (49,0 mm)
For SYLC51836 and SYLC51836-1
Length .................................................................................................... 9.6 in. nominal (243,8 mm nominal)
For SYLC51836-10
Length .................................................................................................. 8.35 in. nominal (212,09 mm nominal)
Weight ................................................................................................................................ 0.65 lbs. (0,30 kg)
Electrical Stroke ......................................................................................... 1.75 to 1.79 in. (44,5 to 45,5 mm)
Mechanical Stroke .............................................................................................................. 1.85 in. (47,0 mm)
Load ...................................................................................................................................... 50 lbs. (22,7 kg)
Stroke Time ......................................................................................................................................... 7.0 sec

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SYLC51836 SERIES
TESTING AND FAULT ISOLATION
1. General.
A. This section contains the procedures and information required for the testing and fault isolation of
the linear actuator. Wiring diagrams are furnished to provide support for testing and fault isolation.
B. You must do the test steps in the same order in which they are written, and with the setup
conditions listed in paragraph 3.
2. Test Equipment.
A. Tools and test equipment that you will need for the tests are listed in Figure 101 and the SPECIAL
TOOLS, FIXTURES, AND EQUIPMENT section.
B. Figures 102, 103 and 104 show the setup of the test fixtures.
3. Pretest Checks and Setup.
A. Examine Documentation.
Before you start testing, look at the reject tags or other information that may be with the unit. The
information on the reject tags may help determine what is wrong with the linear actuator and what
testing is required.
B. Troubleshooting Procedure.
The following troubleshooting procedure will be helpful to you in finding failures with the linear
actuator. Once the cause of failure is determined, it will be easier to choose the correct way to
repair it.
(1) Do the checks listed in the CHECK section. You should be able to see the cause of the failure.
(2) Do the operational checks listed paragraph 4.
(3) Use the troubleshooting guide in Figure 105 to identify subassembly failures.
(4) When you find a failed part, replace it as detailed in the REPAIR section.
(5) After repairing the linear actuator, set up the test equipment and conditions to complete the
functional test.
(6) Do the operational checks listed in paragraph 4 to verify proper operation.
C. Pretest Checks.
See the CHECK section.
Testing and Fault Isolation

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SYLC51836 SERIES
D. Setup of Test Equipment.
NOTE: The instruments listed in Figure 101 are calibrated per ISO-10012-1.
(1) Refer to Figure 101 and the SPECIAL TOOLS, FIXTURES, AND EQUIPMENT section for the
required equipment for testing and troubleshooting.
NOTE: Equivalent substitutes may be used for noted items listed in Figure 101.
NOTE: Vendor Commercial and Governmental Entity (CAGE) codes (preceded by a V) identify part
vendors.
NOTE: Use the following internet address to access the Defense Logistics Information Service for
vendor CAGE codes and addresses: http://www.dlis.dla.mil/bincs/default.asp.
ITEM / PART NO. SPECIFICATION / DESCRIPTION SOURCE

DC Ammeter 0-1.0 Adc, 0.5% full scale accuracy Commercially available
DC Power Supply 0-30 Vdc, 5 amp min., DC power source Commercially available
DC Voltmeter 0-30 Vdc, 0.5% full scale accuracy Commercially available
Dial Indicator 2.000 in. (50,8 mm) travel, 0.5% full scale Commercially available
accuracy
Fixture NYLZ51513 Running test fixture Smiths Aerospace - Rockford
Fixture PYLZ51196 Hydraulic test fixture 1354 Clifford Avenue
P.O. Box 2909
(V05624)
Force Gage DPPH- Factory specification, force gage indicator Chatillon, John and Sons, Inc.
250 (V11710)
Insulation Factory specifications, insulation LEM Instruments, Inc.
Resistance Tester resistance tester (V1JHT9)
Model Unilap ISO-X
Model 87 (2) Factory specifications, digital multimeter Fluke Electronics Corp.
(DMM) Pomona Electronics Division
(V89536)
Test Cable Connect linear actuator to running test Locally manufactured
fixture
Test Bar Hydraulic test fixture setup Smiths Aerospace - Rockford
PYLZ-53380 or 1354 Clifford Avenue
PYLZ-53381 P.O. Box 2909
(V05624)
Threaded Rod 5/16-24 thread & ½-13 thread X 1-inch Locally manufactured
long
Timer 0.2 second accuracy per operation, electric Commercially available
timer
Tools and Test Equipment

Figure 101

Page 102
21-25-03 Jan 23/2004
SYLC51836 SERIES
Running Test Fixture, NYLZ51513

Figure 102
Test Cable Schematic For SYLC51836-1

Figure 103

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21-25-03 Sep 14/01
SYLC51836 SERIES
APPROXIMATELY
3 FT (0,9M)
TO
A 1 CW JACK
B 2 CCW JACK
LINEAR C 3 COM JACK
ACTUATOR D 4 +28 VDC JACK
CONNECTOR E 5 L1(+) JACK
F 6 L2(+) JACK
AWG 22 GAUGE
INSULATED WIRES
CONNECTOR
P/N 26FB98JN OR 26FB98SN
Test Cable Schematic For SYLC51836 and SYLC51836-10

Figure 104
LOAD DIRECTION DIAL

LEVER INDICATOR
HYDRAULIC
CYLINDER LINEAR
HYDRAULIC FORCE
ACTUATOR GAUGE
POWER PACK
COMPRESSION TENSION
51836105.CDR
TEST BAR
Hydraulic Test Fixture, PYLZ51196

Figure 105

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21-25-03 Sep 14/01
SYLC51836 SERIES
1.00 (25.4)
0.255
0.245 ( 6,223
6,477
)
7.190
+0.0005
-0.0005 (
182.626
+0.0127
-0.0127 )
MATERIAL - 0.50 (12.7) STEEL
0.2505
0.2500 ( 6,3500
6,3627
) INSIDE DIAMETER
HARDENED BUSHINGS (2)
51836007a.CDR
1.00 (25.4)
Dimensions in inches (millimeters)
Figure 106
Test Bar PYLZ-53380
(
0.2505 6.362
)
0.2500 6.350 INSIDE DIAMETER
HARDENED BUSHING
0.245–0.255
(6,22–6,48)
0.120–0.130
(3,05–3,30)
0.745–0.755
(18,92–19,18)
0.495–0.505 RADIUS
(12,57–12,83)
0.245–0.255
(6,22–6,48)
6.2595–6.2605
(158,99–159,02)
0.3125–24 THREAD
0.75 MIN. DEEP 6.7595–6.7605
(19,05 MIN.) (171,69–171,72)
0.495–0.505 MATERIAL - 0.50 SQUARE STEEL

(12,57–12,83)
Dimensions in inches (millimeters) 51836007.CDR
Figure 107
Test Bar PYLZ-53381

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21-25-03 Jan 23/2004
SYLC51836 SERIES
WARNING: DO NOT APPLY POWER TO THE UNIT OR TEST FIXTURE WHILE YOU
CONNECT THE TEST SETUP.
(2) No power shall be applied to the unit or assembly while being inserted in or connected to the
test setup.
(3) Connect voltmeter, ammeter, timer and DC power supply to test fixture per Figure 102.
(4) Place running test fixture switches in following positions:
(a) Switch S1 in the OFF position.
(b) Switch S2 in the clockwise (EXT) position.
(c) Switch S3 in the PM position.
(5) For SYLC51836 and SYLC51836-10, connect running test fixture test cable to the linear
actuator per Figure 104 and jumper L1(-) into COM and jumper L2(-) into COM.
(6) For SYLC51836-1, connect running test fixture test cable to the linear actuator, digital
multimeters (DMM), and running test fixture per Figure 103.
(7) For SYLC51836-1, set DMM 1 and DMM 2 to DIODE position.
(8) Zero dial indicator as follows:
(a) For SYLC51836 and SYLC51836-1, install test bar PYLZ-53380 (Figure 106) in hydraulic
test fixture (Figure 105).
(b) For SYLC51836-10, install test bar PYLZ-53381 (Figure 107) in hydraulic test fixture
(Figure 105) as follows:
1 Manufacture locally a 1-inch long piece of rod that has a 5/16-24 thread on one end
and a ½-13 thread on the other.
2 Thread the piece of rod into one side of the test fixture.
3 Thread the threaded end of the test bar (PYLZ-53381) onto the other end of the
threaded rod until the test bar bottoms against the test fixture.
(c) Set dial indicator to zero (0).
(d) Remove test bar from hydraulic test fixture.
(9) Mount linear actuator in hydraulic test fixture.
(10) Adjust DC power supply output to 27.5 to 28.5 Vdc.
E. Test Decision.
The correct results of a test are given in each step. Failure of the linear actuator to meet correct
results is cause to reject the unit, or to start repair procedures.

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SYLC51836 SERIES
F. Test Conditions.
(1) Ambient temperature shall be 65 to 95°F (18 to 35°C).
(2) Ambient atmospheric pressure shall be approximately 29.92 in. Hg.
4. Linear Actuator Operational Check.
A. Check end play of the linear actuator as follows:
(1) Adjust hydraulic test fixture load to approximately 10 lbs. (4,5 kg).
(2) Apply 10 lbs. (4,5 kg) hydraulic test fixture load on linear actuator.
(3) Set hydraulic test fixture load direction lever to COMPRESSION.
(4) Set running test fixture switch S1 to ON position.
(5) Press running test fixture switch S4 until linear actuator runs to approximately mid-stroke. Note
dial indicator reading.
(6) Set hydraulic test fixture load direction lever to TENSION. Note dial indicator reading. The
difference between two readings (end play) shall not exceed 0.010 in. (0,254 mm).
B. Increase hydraulic test fixture load to 50 lbs. (22,7 kg).
C. Place running test fixture switch S2 to CCW (RET) position.
D. Press running test fixture switch S4 until linear actuator runs to RETRACT position.
E. For SYLC51836 and SYLC51836-10, running test fixture diode L1 is ON.
F. Set the timer to zero (0).
G. Apply 50 lbs. (22,7 kg) hydraulic test fixture load to linear actuator.
H. Set hydraulic test fixture load direction lever to COMPRESSION.
I. Check electrical extend performance as follows:
(1) Place running test fixture switch S2 to CW (EXT) position.
(2) Press running test fixture switch S4 until linear actuator runs to EXTEND position.
(a) For SYLC51836 and SYLC51836-10, running test fixture diode L1 is OFF and diode L2 is
ON.
(b) Observe ammeter during linear actuator movement. Current shall not exceed 0.65 amps.
(c) Time to move from full RETRACT to full EXTEND position shall not exceed 7.0 seconds,
maximum.

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(3) For SYLC51836 and SYLC51836-1, take dial indicator reading. Add this reading to 7.190 in.
(182,63 mm). The result shall be 8.960 to 9.020 in. (227,58 to 229,11 mm).
(4) For SYLC51836-10, take dial indicator reading. Add this reading to 6.290 in. (159,77 mm).
The result shall be 8.030 to 8.090 in. (203,96 to 205,49 mm).
J. Check electrical retract performance as follows:
(1) Set timer to zero (0).
(2) Set hydraulic test fixture load direction lever to TENSION.
(3) Place running test fixture switch S2 to CCW (RET) position.
(4) Press running test fixture switch S4 until linear actuator runs to RETRACT position.
(a) For SYLC51836 and SYLC51836-10, running test fixture diode L1 is ON and diode L2 is
OFF.
(b) Observe ammeter during linear actuator movement. Current shall not exceed 0.65 amps.
(c) Time to move from full EXTEND to full RETRACT position shall not exceed 7.0 seconds,
maximum.
(5) For SYLC51836 and SYLC51836-1, take dial indicator reading. Add this reading to 7.190 in.
(182,63 mm). The result shall be 7.190 to 7.250 in. (182,63 to 184,15 mm).
(6) For SYLC51836-10, take dial indicator reading. Add this reading to 6.290 in. (159,77 mm).
The result shall be 6.260 to 6.320 in. (159,00 to 160,53 mm).
K. For SYLC51836 and SYLC51836-1, subtract reading taken in step J.(5) from reading taken in step
I.(3). The result shall be 1.750 to 1.790 in. (44,45 to 45,47 mm). This is the total stroke of the linear
actuator.
L. For SYLC51836-10, subtract reading taken in step J.(6) from reading taken in step I.(4). The result
shall be 1.750 to 1.790 in. (44,45 to 45,47 mm). This is the total stroke of the linear actuator.
M. Check stroke between extend indication and end of travel (extend direction) as follows:
(1) Set hydraulic test fixture load direction lever to TENSION.
(2) Place running test fixture switch S1 to the OFF position.
(4) Press running test fixture switch S4 until linear actuator moves approximately 0.50 in.
(12,7 mm).
(5) For SYLC51836 and SYLC51836-10, watch running test fixture diode L2 while moving linear
actuator in EXTEND direction. Press running test fixture switch S4 until diode L2 comes ON
and diode L1 is OFF.

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SYLC51836 SERIES
(6) For SYLC51836-1, watch DMM 1 display while moving linear actuator in EXTEND direction.
Press running test fixture switch S4 until DMM 1 display indicates a voltage as opposed to an
open.
(7) For SYLC51836-1, check DMM 2 display. It shall indicate an open.
(8) Take dial indicator reading and record it.
(9) Place running test fixture switch S1 to the ON position.
(10) Press running test fixture switch S4 until linear actuator runs to EXTEND position. Ensure
linear actuator goes to full EXTEND position.
(11) Take dial indicator reading. The difference between this reading and the reading taken in step
(8) shall be 0.010 to 0.020 in. (0,25 to 0,51 mm).
N. Remove load from hydraulic test fixture.
O. For SYLC51836-1, perform insulation resistance measurement as follows:
(1) Press running test fixture switch S4 until linear actuator runs to approximately mid-stroke.
(2) Place running test fixture switch S1 in OFF position.
(3) Remove test cable from linear actuator connector.
(4) Use jumper wire to short linear actuator connector pins A and B together.
(5) Use insulation resistance tester to apply 50 Vdc between connector shell and pins A/B. There
shall be a minimum of 20 megohms resistance.
(6) Remove jumper wires from linear actuator connector.
(7) Connect test cable to linear actuator connector.
(8) Place running test fixture switch S2 to CCW (RET) position.
(9) Place running test fixture switch S1 in ON position.
(10) Press running test fixture switch S4 until linear actuator runs to RETRACT position.
(13) Use insulation resistance tester to apply 50 Vdc between connector shell and pin B. There
(14) Use jumper wire to short linear actuator connector pins D, E and F together.
(15) Use insulation resistance tester to apply 500 Vdc between connector shell and pins D/E/F.
There shall be a minimum of 20 megohms resistance.

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(16) Remove jumper wires from linear actuator connector.
(17) Connect test cable to linear actuator connector.
(19) Place running test fixture switch S1 in ON position.
(20) Press running test fixture switch S4 until linear actuator runs to EXTEND position.
(23) Use insulation resistance tester to apply 50 Vdc between connector shell and pin A. There
(24) Use jumper wire to short linear actuator connector pins D, E and F together.
(25) Use insulation resistance tester to apply 500 Vdc between connector shell and pins D/E/F.
There shall be a minimum of 20 megohms resistance.
(26) Remove jumper wire between linear actuator connector pins D, E and F.
(27) Use insulation resistance tester to apply 500 Vdc between linear actuator case ground and pin
C. There shall be a complete breakdown.
P. Remove linear actuator from running and hydraulic test fixtures.
5. Troubleshooting Guide.
A. Refer to Figure 108 for troubleshooting guide used with the test procedure.
B. Refer to Figure 109 for linear actuator schematic.

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SYLC51836 SERIES
PROBLEM CAUSE CORRECTIVE ACTION
Actuator end play exceeds limits. Excessive end play in thrust Add shim washers (400 or 410)
bearing (440). as required.
Actuator stays at RETRACT Defective switch(es) (140 or 180). Replace defective switch(es)
or EXTEND position, does not (140 or 220).
move. Defective motor assembly (510). Replace motor assembly (510).
Actuator stroke time not within Defective motor assembly (510). Replace motor assembly (510).
limits. Misaligned or defective bearings Replace bearings (360 or 460) or
(360 or 460) or thrust bearing thrust bearing (440).
(440).
Defective gear train. Replace gear assemblies (380 or
390).
Insufficient end play. Add shim washers (400 or 410)
as required.
Linear actuator running current Defective motor assembly (510). Replace motor assembly (510).
exceeds limits. Defective low pass EMI filters (130 Replace low pass EMI filters (130
and/or 500). and/or 500).
Grinding noises. Misaligned or defective gear Replace gears assemblies (380
assemblies (380 and 390). and 390) and jackscrew (450).
Gear train failure. Replace gear assemblies (380
and 390) and jackscrew (450).
Misaligned or defective bearings Replace bearings (360 or 460) or
(360 or 460) or thrust bearing thrust bearing (440).
(440).
Defective motor assembly (510). Replace motor assembly (510).
No continuity between connector Connector (270) pin 3 not Check pin-to-wire connection,
(270) pin 3 and connector shell. grounded. and/or connection at terminal
(120).
Insulation resistance does not Exposed conductor. Check for pinched wires or cut
meet limits. insulation.
Testing and Troubleshooting for Linear Actuator

Figure 108

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SYLC51836 SERIES
Linear Actuator Schematic

Figure 109

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SYLC51836 SERIES
AUTOMATIC TEST REQUIREMENTS
1. General.
NOTE: The linear actuator is designed for manual testing as defined in the preceding TESTING AND
FAULT ISOLATION section. It is not designed for testing with automatic test equipment.
Not applicable.
Automatic Test Requirements

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SYLC51836 SERIES
DISASSEMBLY
1. General.
A. This section contains disassembly procedures for the linear actuator. To prevent equipment
damage and personal injury, read all warnings, cautions and notes carefully.
B. Make sure the work area is well lighted and clean.
CAUTION: DISASSEMBLE THE LINEAR ACTUATOR ONLY AS FAR AS NECESSARY FOR

REPAIR. DISASSEMBLE ONLY AS FAR AS NECESSARY TO REMOVE AND
REPLACE DAMAGED COMPONENTS.
C. Keep all parts with their related assemblies.
D. If you cannot see damage, corrosion, or contamination, use the TESTING AND FAULT ISOLATION
section to test the linear actuator.
E. Tag electrical leads before unsoldering and disconnecting them from components.
F. Refer to the IPL for an illustration of the linear actuator. Numbers in parentheses ( ) refer to item
numbers on the illustration.
G. Tools required for disassembly are listed in Figure 301.
EQUIPMENT SOURCE
Soldering Iron Commercially Available
Wire Cutters Commercially Available
Exacto Knife Commercially Available
Disassembly Equipment
Figure 301
2. Removal of Nameplate.
A. For SLYC51836 only. Do not remove nameplate (60, IPL Figure 1) unless damaged.
B. See the REPAIR section for instructions on replacement.
3. Disassembly of Linear Actuator.
A. Remove cover (30) as follows:
CAUTION: HOLD END BODY ASSEMBLY WHEN LOOSENING JAM NUT TO PREVENT
(1) For SYLC51836 and SYLC51836-1, remove rod-end assembly (10) and jam nut (20) from
moving tube assembly (480).
Disassembly
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SYLC51836 SERIES
(2) Remove two screws (40), lockwashers (50) and cover (30) from moving tube housing (530).
B. Remove low pass EMI filter (130) as follows:
(1) Unsolder wires from low pass EMI filter (130).
(2) Remove two screws (80), nuts (90), lockwashers (100) and one terminal (120) from filter
support clip (70) and stop (110).
(3) Remove filter support clip (70), stop (110) and low pass EMI filter (130) from moving tube
housing (530).
(4) Remove nut and low pass EMI filter (130) from filter support clip (70).
C. Remove extend limit switch S2 (140) as follows:
(1) Unsolder wires from switch (140). Refer to the REPAIR section for detailed instructions.
(2) Remove two screws (150) that secure switch (140), switch actuator (160) and switch insulator
(170) from moving tube housing (530).
D. Remove extend indicator switch S3 (180) as follows:
E. Remove retract limit switch S1 (220) as follows:
F. Remove connector (270) as follows:
(1) Cut lock wire and remove two screws (280), screw (290), and screw (300) that secure
connector (270) to connector block (310) and ear gear plate (330).
(2) Remove terminal (260) from screw (280).
(3) Carefully pull connector (270) away from connector block (310) as far as wires allow.
G. Remove connector block (310) from rear gear plate (330).
H. Remove gear train as follows:
(1) Remove three screws (340) that secure rear gear plate (330) to moving tube housing (530).
(2) Remove rear gear plate (330) from moving tube housing (530). Use care to avoid dropping
gear assemblies (380 and 390) and shim washers (370).
Disassembly
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SYLC51836 SERIES
(3) Remove gear assemblies (380 and 390), shim washer (370B) and bearings (360) from rear
gear plate (330).
(4) Remove shim washers (400 and 410), two thrust washers (430) and thrust bearing (440) from
jackscrew (450).
(5) Unscrew jackscrew (450) from moving tube assembly (480).
(6) Remove jackscrew (450) and moving tube assembly (480) from moving tube housing (530).
(7) Remove two thrust washers (430) and thrust bearing (440) from jackscrew (450).
I. Disassemble moving tube housing (530) and motor assembly (510) as follows:
(1) If required, remove bearing (460) from moving tube housing (530).
(2) If required, remove bearings (360) from moving tube housing (530).
(3) Remove low pass EMI filter (500) from moving tube housing (530) as follows:
(a) Unsolder wires from low pass EMI filter (500).
NOTE: Low pass EMI filter is attached to moving tube housing with epoxy adhesive.
(b) Remove low pass EMI filter (500) from moving tube housing (530).
(4) Remove two screws (520) and motor assembly (510) from moving tube housing (530).
J. If required, remove three adjusting screws (490 and 495) from moving tube assembly (480).
K. Remove preformed packing (470) from moving tube assembly (480). Discard preformed packing
(470).
Disassembly
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SYLC51836 SERIES
CLEANING
1. General.
A. Solvents required for cleaning are listed in Figure 401. Equipment required for cleaning is listed in
Figure 402.
B. If routing of wires or cabling is disturbed during cleaning, restore wires and cabling to proper
positions after cleaning.
vendors.
MATERIALS SOURCE
DS-108 Solvent, per P-W-2891 Dynamold Solvents, Inc.
(V30256)
Cleaning Materials
Figure 401
EQUIPMENT SOURCE
Cleaning Cloth Commercially Available
Soft Bristle Brush Commercially Available
Cleaning Equipment
Figure 402
2. Cleaning of Connector.
WARNING: PERFORM SOLVENT CLEANING IN AN APPROVED CLEANING CABINET OR IN A

WELL-VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS. AVOID
EYE AND REPEATED SKIN CONTACT. KEEP SOLVENTS AWAY FROM SPARKS,
FLAMES AND OTHER IGNITION SOURCES.
WARNING: DS-108 SOLVENT IS TOXIC AND COMBUSTIBLE. DO NOT BREATHE VAPORS. USE
IN A WELL-VENTILATED AREA FREE FROM SPARKS, FLAME OR HOT SURFACES.
WEAR SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES AND OTHER
PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH WATER AND SEEK
MEDICAL AID. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
CAUTION: DO NOT ALLOW CLEANING SOLVENT OF ANY KIND TO COME IN CONTACT WITH
ANY NYLON, RUBBER OR ELECTRICAL PART.
A. Wipe dust and dirt from connector body, shell and cable clamps with soft cloth dampened with
DS-108. Wipe dry with a clean lint-free cloth.
Cleaning
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SYLC51836 SERIES
PARTICLES THAT MAY ENTER THE EYES. PRESSURE MUST NOT EXCEED 30
PSIG (206,8 KPA) AND THEN ONLY WITH EFFECTIVE CHIP GUARDING AND
PERSONAL PROTECTIVE EQUIPMENT. DO NOT DIRECT COMPRESSED AIR
TOWARD YOURSELF OR ANYONE ELSE.
B. Remove dust from inserts using a small, soft-bristle brush and clean compressed air.
C. Wash any dirt and traces of lubricant from inserts, insulation, and contacts using DS-108 applied
with a small, soft-bristle brush.
D. Dry inserts, insulation, and contacts with clean compressed air.
3. Cleaning of Electrical and Nonmetallic Parts.
A. Clean electrical and nonmetallic parts with a soft-bristle brush.
B. Blow foreign particles from the part using a stream of dry, filtered, low-pressure compressed air.
C. Wipe parts clean with a clean, dry, lint-free cloth.
4. Cleaning of Bearings and Assemblies Containing Bearings.
Clean bearings and assemblies containing bearings with a clean, dry, lint-free cloth.
Cleaning
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SYLC51836 SERIES
5. Cleaning of All Other Metallic Parts.
CAUTION: DO NOT ALLOW CLEANING SOLVENT OF ANY KIND TO COME IN CONTACT WITH
ANY NYLON, RUBBER, OR ELECTRICAL PART.
A. Use a clean lint-free cloth dipped in DS-108 to clean other metal parts. Make sure all sealant is
removed from parts.
B. Blow foreign particles from the part using a stream of dry, filtered, low-pressure compressed air.
Cleaning
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SYLC51836 SERIES
CHECK
1. General.
A. Visually check all parts for scratches, corrosion, nicks, cracks, foreign matter, breaks or obvious
wear or damage. Refer to the FITS AND CLEARANCES section for applicable wear tolerances.
Malfunction and/or rejection tags should be evaluated to help determine if repair is feasible.
B. Use ultraviolet light to check for contamination of connector pin and sockets. If contamination is
found, remove contamination. Refer to the CLEANING section for detailed instructions.
C. Refer to the IPL for an illustration of the linear actuator. Numbers in parentheses ( ) refer to item
Equipment required for checking is listed in Figure 501.
vendors.
ITEM DESCRIPTION/SPECIFICATION SOURCE

Model 87 or equivalent Digital multimeter (DMM), factory Fluke Electronics Corp.
specifications (V89536)
Check Equipment
Figure 501
2. Check Criteria.
Specific check criteria are listed in Figure 502.
CHECK ACTION/CRITERIA RESPONSE

Motor assembly (510) Check pinion for chipped or Replace motor assembly
missing teeth. (510).
Switch actuator(s) (160, 200, 240) Check for broken or cracked Replace switch actuator(s)
actuator tab. (160, 200, 240).
Switch(es) (140, 180, 220) Check for proper operation, Replace switch(es) (140, 180,
electrical continuity. 220).
Connector (270) Check for proper solder Replace connector (270) or
connections and damaged pins. connector pins.
Bearing (360) Check for excessive wear and for Replace bearing (360).
binding and seizure.
Gear assemblies (380 and/or 390) Check for excessive wear and Replace gear assemblies (380
chipped or missing teeth. and/or 390).
Jackscrew (450) and moving tube Check for excessive wear and Replace jackscrew (450)
assembly (480) damaged threads. and/or moving tube assembly
(480).
Helicoil insert(s) (320, 350, and 540) Check for broken or cross- Replace helicoil insert(s) (320,
threaded helicoil insert(s) (320, 350, and/or 540).
350, and 540).
Linear Actuator Check Criteria
Figure 502
Check
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SYLC51836 SERIES
3. Inspection of Switches.
A. Connect DMM to terminals on each end of switch (140, 180, or 220).
B. Set DMM to lowest resistance setting. The DMM should indicate zero ohms.
C. Press on switch actuator (160, 200, or 240) to actuate switch plunger. There should be an audible
clicking sound.
D. Press and hold switch actuator (160, 200, or 240). The DMM should now indicate infinite resistance
(open circuit).
E. Repeat steps A. through D. for all switches (140, 180, or 220).
F. Replace defective switches (140, 180, or 220). Refer to the DISASSEMBLY and ASSEMBLY
sections for detailed instructions.
Check
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SYLC51836 SERIES
REPAIR
1. General.
A. This section contains repair practices and procedures for performing repair tasks that require step-
by-step processes.
B. The decision to repair the linear actuator is made by the repair facility and is based on the CHECK
section information and practicality of repair. The procedures contained in this section may not be
feasible or practical for all operators, and are not mandatory. Units not meeting the CHECK section
requirements must be replaced if repair is not possible.
C. Refer to the IPL for an illustration of the linear actuator. Numbers in parentheses ( ) refer to item
D. Required materials to accomplish repairs are listed in Figure 601.
E. Required tools/equipment to accomplish repairs are listed in Figure 602.
NOTE: Equivalent substitutes may be used for noted items listed in Figure 601 and 602.
vendors.
MATERIALS SOURCE
Epoxy Adhesive, E-20HP Henkel Loctite Corporation
(V05972)
Alodine No. 1200S (Chemical Conversion Coating) Chemical Commodities Agency, Inc.
(V60777)
Heat Shrink Tubing Commercially Available
Isopropyl Alcohol, TT-I-735 Commercially Available
Solder, SN63-W-RA-P3 per QQ-S-571 Frys Metals, Inc.
(V96613)
DELETED
Wire, MIL-W-16878/4 (Colors as denoted by wiring Commercially Available
diagram)
Repair Materials
Figure 601
Repair
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SYLC51836 SERIES
TOOLS/EQUIPMENT SOURCE
Heli-Coil Extracting Tool, P/N 1227-06 or equivalent Emhart Corporation
Heli-Coil Division
Heli-Coil Insertion Tool, P/N 7551-04 or equivalent (V1D1Q0)
Heli-Coil Tang Break-off Tool P/N 3695-04 or equivalent
Precision Wire Strippers or Thermal Wire Strippers Commercially Available
Wire Cutters Commercially Available
Repair Equipment
Figure 602
2. General Repair Practices.
A. Use wire cutters as follows:
(1) The wire cutters should have a single-bevel cutting edge. Use of this type of wire cutter when
clipping the lead above the solder eliminates physical shock to the solder connection. Physical
shock reduces solder connection reliability.
(2) The leads should be cut off 0.010 to 0.030 in. (0,25 to 0,76 mm) above the solder.
(3) The wire cutters shown leave a smooth square end on the lead instead of a dangerous sharp
end.
B. Use solder removal equipment as follows:
CAUTION: USE AN ISOLATED LOW-WATTAGE CONTROLLED HEAT SOLDERING IRON TO

PREVENT DAMAGING WIRES AND/OR COMPONENTS DURING SOLDER
REMOVAL.
(1) Solder removal equipment is required when repairing electronic devices. The equipment can
be active or passive.
(2) Active solder removal equipment.
(a) Active solder removal equipment usually consists of a vacuum-producing device with an
associated heat source such as a soldering iron.
(b) The vacuum-producing device can be a complex piece of equipment that uses shop air
pressure to produce a continuous or pulsing vacuum or a simple bulb attached to a
heat-resistant tube heated by a soldering iron.
(3) Passive solder removal equipment.
(a) Passive solder removal may be accomplished using fluxed copper braid.
(b) The copper braid is heated while touching the soldered connection. When the copper
braid is heated, capillary action causes the solder to wick up into the copper braid. The
soldering iron does not come in direct contact with the wiring, thus reducing the amount of
heat transferred to the wiring.
Repair
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SYLC51836 SERIES
C. Strip insulation as follows:
(1) Cut lead or wire to proper length for installation.
(2) Determine the length of insulation to be removed. For soldered leads or wires, include
clearance between the trimmed end of the insulation and the nearest point of the terminal or
connection to which the lead or wire is to be soldered. Clearance for soldered connections
should be as follows:
(a) Minimum clearance should be such that insulation will not be embedded in solder joint and
contour of conductor will be visible at trimmed end of insulation after soldering is
completed.
(b) Maximum clearance should be twice the outside diameter of the insulated wire or leads.
For wires of different diameters terminated at the same soldered joint, the larger outside
diameter should be used to determine the maximum insulation clearance.
WARNING: THERMAL STRIPPERS SHOULD BE USED ONLY IN WELL-VENTILATED AREAS

TO PROTECT PERSONNEL AGAINST TOXIC FUMES GENERATED BY
INSULATING MATERIALS SUCH AS POLYTETRAFLUOROETHYLENE (TEFLON)
OR POLYVINYLCHLORIDE.
(3) Use a thermal stripper or precision-type cutting stripper to remove length of insulation
determined in step (2). When using precision-type cutting stripper to remove insulation from
stranded wire, twist wire in the direction of the lay during stripping operation.
NOTE: A thermal stripper is the preferred tool to remove insulation from leads and wires. A
precision-type cutting stripper may also be used. Knives, scissors, pliers-type
strippers, or similar tools should not be used.
NOTE: Precision-type cutting strippers should be calibrated periodically and whenever

blades are replaced.
(4) After stripping, check stripped ends of leads or wires for damage according to the following
criteria:
(a) Solid insulated wire should not be nicked or cut.
(b) Stranded insulated wire should have no severed or damaged strands.
Repair
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SYLC51836 SERIES
WARNING: DS-108 SOLVENT IS TOXIC AND COMBUSTIBLE. DO NOT BREATHE
VAPORS. USE IN A WELL-VENTILATED AREA FREE FROM SPARKS,
FLAME OR HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-
RESISTANT GLOVES AND OTHER PROTECTIVE GEAR. IN CASE OF EYE
CONTACT, FLUSH WITH WATER AND SEEK MEDICAL AID. IN CASE OF
SKIN CONTACT, WASH WITH SOAP AND WATER.
(c) After stripping, avoid touching stripped ends with bare hands except to restore disturbed
lay of stranded wire. If stripped ends are touched with bare hands, clean using DS-108
solvent and a hard-bristled brush to remove skin oils.
(d) If stripped wires are to be stored for more than 30 days before using, protect wires from
atmosphere by sealing in a plastic bag or other suitable container.
D. Repair scratched aluminum parts as follows:
(1) Mask or remove any nonaluminum items assembled into the aluminum part being treated
unless the nonaluminum part is stainless steel.
WARNING: ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. DO NOT BREATHE

VAPORS. USE IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR
HOT SURFACES. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES,
AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT FLUSH WITH
WATER AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT, WASH
WITH SOAP AND WATER.
(2) Clean the scratched area with isopropyl alcohol. Allow the part to dry completely.
WARNING: ALODINE NO. 1200S (CHEMICAL CONVERSION COATING) IS TOXIC AND

CORROSIVE TO HUMAN TISSUE. WASH THE SKIN THOROUGHLY IF
EXPOSURE OCCURS. IF SOLUTION GETS IN THE EYES, FLUSH WITH WATER
FOR 15 MINUTES AND SEEK MEDICAL HELP IMMEDIATELY. USE IN A WELL-
VENTILATED AREA. WEAR SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES AND OTHER PROTECTIVE GEAR. KEEP ALODINE 1200S AWAY FROM
ACIDS. RINSE APPLICATOR WITH WATER BEFORE DISPOSAL. DO NOT
ALLOW ORGANIC MATERIALS TO BECOME WET WITH ALODINE 1200S AS
THEY WILL BECOME SERIOUS FIRE HAZARDS WHEN DRY. ALODINE 1200S IS
A FIRE HAZARD WHEN DRY.
(3) Dip the part in a bath of chemical conversion coating, Alodine No. 1200S.
(4) Rinse the part thoroughly in hot water.
WARNING: COMPRESSED AIR USED FOR CLEANING OR DRYING CAN CREATE

AIRBORNE PARTICLES THAT MAY ENTER THE EYES. PRESSURE MUST NOT
EXCEED 30 PSIG (206,8 KPA) AND THEN ONLY WITH EFFECTIVE CHIP
GUARDING AND PERSONAL PROTECTIVE EQUIPMENT. DO NOT DIRECT
COMPRESSED AIR TOWARD YOURSELF OR ANYONE ELSE.
(5) Dry the part completely inside and out with clean, compressed air.
Repair
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SYLC51836 SERIES
3. Step-by-Step Processes.
NOTE: Each of the following procedures is considered a separate repair process. Repairs to the linear
actuator should be accomplished according to accepted industry standards.
A. Replace Heli-Coil inserts (320, 350, and/or 530) as follows:
(1) Remove and replace a damaged threaded insert (320, 350, 540) as follows:
(a) Remove the damaged threaded insert (320, 350, 540) from its hole in the connector block
(310), rear gear plate (330), or moving tube housing (530) by inserting a Heli-Coil
threaded insert extracting tool from the list in Figure 601.
(b) Using a light hammer, strike the removal tool with a light blow so that the tool grips the
Heli-Coil threaded insert.
(c) Twist the tool to twist out the Heli-Coil threaded insert from the threaded hole.
(d) Chase the threads of the threaded hole, if necessary using the proper sized tap. Clean
out all metal chips formed.
WARNING: ALODINE 1200S (CHEMICAL CONVERSION COATING) IS TOXIC AND

CORROSIVE TO HUMAN TISSUE. WASH THE SKIN THOROUGHLY IF
EXPOSURE OCCURS. IF THE COATING GETS IN THE EYES, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL HELP IMMEDIATELY. USE
IN A WELL VENTILATED AREA. WEAR SPLASH GOGGLES, SOLVENT-
RESISTANT GLOVES, AND OTHER PROTECTIVE GEAR. KEEP COATING
AWAY FROM ACIDS. RINSE APPLICATOR WITH WATER BEFORE
DISPOSAL. DO NOT ALLOW ORGANIC MATERIALS TO BECOME WET WITH
CHEMICAL CONVERSION COATING AS THEY WILL BECOME SERIOUS
FIRE HAZARDS WHEN DRY. THE COATING IS A FIRE HAZARD WHEN DRY.
(e) Apply protective coating to the threads of the aluminum based connector block (310), rear
gear plate (330), or moving tube housing (530), such as chemical conversion coating per
MIL-C-5541 per paragraph 2A.
(f) Install a new Heli-Coil threaded insert as follows:
1 Select the mandrel (Heli-Coil insertion tool) from Figure 601. Retract the mandrel
and place threaded insert in tool, with the drive tang end towards the front of the
tool.
2 Rotate the mandrel through threaded insert until the tang is fully engaged in the
driving contour. Continue to rotate the mandrel until threaded insert is engaged 1
or 2 threads in the body.
3 Place the insertion tool squarely against the tapped hole and rotate the mandrel,
holding the body with one hand until the top of the threaded insert is ¾ to 1-½
pitch (threads) below the part’s surface.
(g) Measure from the surface of the connector block (310), rear gear plate (330), and/or
moving tube housing (530) to the end of the Heli-Coil insert (320, 350, and/or 540) using a
depth gauge. The Heli-Coil insert (320, 350, or 540) should be 0.023 to 0.047 inch (0,58
to 1,19 mm) below the surface.
Repair
Page 605
21-25-03 Sep 14/01
SYLC51836 SERIES
(h) The drive tang must be removed to allow full passage of screw into the threaded insert.
Break off and remove drive tang with the Heli-Coil automatic tang break-off tool listed in
Figure 601. Make sure that the tool has a square end (no chamfer). Place the tang
break-off tool into the assembled threaded insert until it rests on the tang. Holding the tool
squarely, press down firmly until it clicks and snaps tang off. Discard the tang.
B. Repair wiring harness as follows:
(1) Replace damaged wires between connector (270) and other components as follows:
(a) Remove connector pin from connector (270).
(b) Remove connector pin from damaged wire.
(c) Unsolder damaged wire from low pass EMI filter (130 or 500) or switch (180).
(d) Manufacture a new wire. Refer to wiring diagram (Figure 603) for wire color.
WARNING: BEFORE ATTEMPTING ANY SOLDERING, PERSONNEL MUST BE FAMILIAR

WITH TYPICAL SOLDERING PROCEDURES FOR AIRPLANE ELECTRICAL
AND ELECTRONIC WIRING, INCLUDING WARNINGS AND CAUTIONS.
WEAR EYE PROTECTION AND AVOID BREATHING FUMES GENERATED
BY SOLDERING OR SOLVENTS. TO AVOID INGESTION OF POISONOUS
LEAD OXIDE FROM SOLDER, PERSONNEL MUST WASH HANDS BEFORE
SMOKING OR EATING. EYE PROTECTION IS REQUIRED. USE EXTREME
CAUTION TO AVOID BEING BURNED.
(e) Solder new wire to low pass EMI filter (130 or 500) or switch (180).
(f) Install connector pin in connector (270).
(2) Replace damaged wires connected to motor assembly (510) as follows:
NOTE: The wires from the motor are nonreplaceable. If the wires are damaged and cannot
be spliced, replacement of the motor is required.
(a) Unsolder wires from switch (140 and 220).
(b) Cut damaged section of wire from motor assembly (510).
(c) Strip end of motor assembly (510) wire.
(d) If long enough, solder motor assembly (510) wire to switch (140 or 220). If not long
enough to reach switch (140 or 220), proceed as follows:
1 Manufacture an extension wire. Strip 0.3 inch of (7,62 mm) insulation from one end
of wire.
Repair
Page 606
21-25-03 Sep 14/01
SYLC51836 SERIES
Wiring Diagram
Figure 603
2 Splice wire with 0.3 inch (7,62 mm) of insulation removed to motor assembly (510)
wire.
3 Slide heat shrink tubing over splice and heat to shrink.
WARNING: BEFORE ATTEMPTING ANY SOLDERING, PERSONNEL MUST BE

FAMILIAR WITH TYPICAL SOLDERING PROCEDURES FOR AIRPLANE
ELECTRICAL AND ELECTRONIC WIRING, INCLUDING WARNINGS AND
CAUTIONS. WEAR EYE PROTECTION AND AVOID BREATHING
FUMES GENERATED BY SOLDERING OR SOLVENTS. TO AVOID
INGESTION OF POISONOUS LEAD OXIDE FROM SOLDER,
PERSONNEL MUST WASH HANDS BEFORE SMOKING OR EATING.
EYE PROTECTION IS REQUIRED. USE EXTREME CAUTION TO AVOID
BEING BURNED.
4 Strip insulation from other end of wire.
5 Solder wire to switch (140 or 220).
4. Nameplate Replacement.
NOTE: Remove nameplate (60, IPL Figure 1) only if it is damaged or illegible.
NOTE: For SYLC51836-1, -10 only. The nameplate (60, IPL Figure 1) has been deleted from the bill
of materials. Nameplate information is now engraved directly on cover (30).
Repair
Page 607
21-25-03 Feb 18/2004
SYLC51836 SERIES
A. Use sharp knife to cut adhesive bead and pry nameplate (60, IPL Figure 1) from cover (30).
B. To obtain a new nameplate from Smiths Aerospace – Rockford, it will be necessary to provide the
Contracts department with the following information on the unit(s):
(1) Part Number
(2) Revision Letter
(3) Date of Manufacture
(4) Work Order / Project Number
(5) Number of Units
(6) Serial Number(s) of Units
(7) Reason of Need for Replacement
(8) Contact Person and Contact Information
C. Soon thereafter, the Smiths Aerospace – Rockford Quality department will request photographs of
the unit / nameplate so the information listed above may be verified.
D. Smiths Aerospace will send the customer new nameplates, and other materials in a nameplate
“replacement kit”.
E. The new nameplates are to be applied to the unit in the area where the damaged nameplate used to
be. Since the nameplate already has adhesive on the reverse side, there is no need to use
additional adhesive to fasten the nameplate.
F. If the information is already engraved on the cover (40) instead of an actual nameplate, the
replacement nameplate will be placed over the engraved area on the unit.
G. The pictures, removed nameplates, and paperwork, which includes Smiths Aerospace –Rockford
Form # F-Q-206 (Process for Field Replacement of Nameplates) are to be placed in the envelope
that was provided with the nameplate “replacement kit”, and returned to Smiths Aerospace Quality
Department immediately following the completion of the nameplate replacement process. Remove
backing from new self-adhesive nameplate (60). Carefully place nameplate (60) on cover (30). Pay
attention to orientation; nameplate lettering should be legible with connector (270) oriented up.
WARNING: ADHESIVE IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE AND SKIN
CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH
WITH WATER AND SEEK MEDICAL ATTENTION. IN CASE OF SKIN CONTACT,
WASH WITH SOAP AND WATER.
H. Remove backing from new self-adhesive nameplate (60).
I. Carefully place nameplate (60) on cover (30). Pay attention to orientation; nameplate lettering
should be legible with connector (270) oriented up.
J. Carefully apply a small bead of sealant around nameplate edges. Allow adhesive to air dry for four
hours.
Repair
Page 608
21-25-03 Jan 23/2004
SYLC51836 SERIES
ASSEMBLY
1. General.
A. Assembly procedures are provided in this section in the form of text.
B. Storage instructions are included in this section.
C. Torque values for fasteners are listed in the FITS AND CLEARANCES section.
D. Refer to the IPL for an illustration of the linear actuator. Numbers in parentheses ( ) refer to item
E. Required materials to accomplish repairs are listed in Figure 701.
F. Required tools/equipment to accomplish repairs are listed in Figure 702.
NOTE: Equivalent substitutes may be used for noted items listed in Figures 701 and 702.
vendors.
ASSEMBLY MATERIALS SOURCE

Epoxy Adhesive, E-20HP Henkel Loctite Corporation
(V05972)
Cushion and Dunnage, PPP-C-1752, Unicellular, Commercially Available
Polyethylene Foam
Desiccant, MIL-D-3464 Commercially Available
Emery Paper Commercially Available
Grease, Aircraft, General Purpose, Per MIL-PRF- Commercially Available
81322, Grade 2, or equivalent
Lock Wire, MS20995-N32 Commercially Available
Masking Tape, 0.75 in. (19,0 mm) Wide Commercially Available
Plastic Bag Commercially Available
Silicone Adhesive Sealant, 18718 Gasket Maker Henkel Loctite Corporation
(V05972)
Solder, SN-63-W-RA-P3 per QQ-S-571 Frys Metals, Inc.
(V96613)
Polyester Tape, MIL-I-15126, 028 in. (7,1 mm) Wide Commercially Available
Unit Container, PPP-B-636, Type CF or SF, Commercially Available
Class Weather Resistant
Wrapping Material, MIL-B-121, Grade A Commercially Available
Assembly Materials
Figure 701
Assembly
Page 701
21-25-03 Jan 23/2004
SYLC51836 SERIES
TOOLS/EQUIPMENT SOURCE
Cleaning Cloth Commercially Available
Assembly Equipment
Figure 702
2. Assembly.
A. Install preformed packing (470) on moving tube assembly (480).
B. Assemble moving tube housing (530) and motor assembly (510) as follows:
WARNING: EPOXY ADHESIVE IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE

AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN CASE OF EYE
CONTACT, FLUSH WITH WATER AND SEEK MEDICAL ATTENTION. IN CASE
OF SKIN CONTACT, WASH WITH SOAP AND WATER.
CAUTION: USE CARE TO KEEP EPOXY ADHESIVE AWAY FROM MOTOR PINION. EPOXY
ADHESIVE CAN BIND MOTOR PINION AND CAUSE FAILURE OF MOTOR
ASSEMBLY.
(1) Position the motor leads on the motor assembly (510) and fasten them to the motor near the
rear end cap with polyester tape. Apply two wraps of tape around the motor.
(2) Carefully apply a thin bead of epoxy adhesive on the moving tube housing (530) where the
motor assembly (510) touches the housing.
(3) Position motor assembly (510) on moving tube housing (530) and secure with two
screws (520).
(4) If required, install bearing (460) in moving tube housing (530).
(5) Install low pass EMI filter (500) on moving tube housing (530) as follows:
WARNING: ADHESIVE IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT EYE

CONTACT, FLUSH WITH WATER AND SEEK MEDICAL ATTENTION. IN
CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
(a) Screw the EMI filter (500) into the hole in moving tube housing (530). Apply a small patch
of epoxy adhesive to the mating surface between the low pass EMI filter (500) and the
moving tube housing (530).
(b) Remove excess epoxy adhesive with a clean lint-free cloth. Allow epoxy adhesive to air
dry for four hours.
C. Install extend limit switch S2 (140) as follows:
(1) Position switch insulator (170), switch actuator (160), and switch (140) on moving tube housing
(530) and secure with two screws (150).
Assembly
Page 702
21-25-03 Sep 14/01
SYLC51836 SERIES
D. Install extend indicator switch S3 (180) as follows:

(1) Coat mating surface of switch actuator (200) near screw holes with epoxy adhesive.
(2) Position switch insulator (210), switch (180), and switch actuator (200) on moving tube housing
(530) and secure with two screws (190). Make sure epoxy adhesive does not exceed height of
heads of two screws (190). Allow epoxy adhesive to air dry for four hours.
E. Install retract limit switch S1 (220) as follows:
(1) Position switch insulator (250), switch actuator (240), and switch (220) on moving tube housing
(530) and secure with two screws (230).
F. Install low pass EMI filter (130) as follows:

(1) Position filter support clip (70), stop (110), and low pass EMI filter (130) on moving tube
housing (530).
(2) Use two screws (80), nuts (90), lockwashers (100) and one terminal (120) to secure filter
support clip (70) and stop (110) to moving tube housing (530).
(3) Place low pass EMI filter (130) in hole in filter support clip (70). Use nut to secure low pass
EMI filter (130) to filter support clip (70).
(4) Apply a small patch of adhesive between the nut of the low pass EMI filter (130) and the filter
clip (70). Allow epoxy adhesive to air dry for four hours.
G. Install gear train as follows:
(1) Coat rubbing surfaces of thrust washers (430), thrust bearing (440) and jackscrew (450) with
grease. Do not grease thrust washer (430) rubbing surface that will interface with
bearing (460).
(2) Install two thrust washers (430) and thrust bearing (440) on jackscrew (450).
(3) Liberally apply grease to jackscrew (450) threads.
(4) Position moving tube assembly (480) in moving tube housing (530).
(5) Thread jackscrew (450) into moving tube assembly (480).
(6) Coat rubbing surfaces of shim washers (400 and 410), thrust washers (430), thrust bearing
(440) and jackscrew (450) with grease.
Assembly
Page 703
21-25-03 Jan 23/2004
SYLC51836 SERIES
(7) Install shim washers (400 and 410), two thrust washers (430) and thrust bearing (440) in rear
gear plate (330).
(8) If removed, install bearings (360) in rear gear plate (330).
(9) If removed, install bearings (360) in moving tube housing (530). Ensure bearing (360) does not
interfere with motor assembly (510) pinion.
(10) Coat rubbing surfaces of shim washer (370B) and gear assemblies (380 and 390) with grease.
Do not grease shim washer surfaces or gear assembly surfaces that will interface with bearings
(360).
(11) Install shim washer (370B) on small gear side of gear assembly (390).
(12) Deleted
(13) Install gear assembly (380) in moving tube housing (530). Ensure that teeth of large gear in
gear assembly (380) mesh with motor assembly (510) pinion teeth.
NOTE: When installing gear assembly (390) it may be necessary to back out the jackscrew (450) to
provide clearance for inserting the gear assembly into the moving tube housing (530).
(14) Install gear assembly (390) in moving tube housing (530). Ensure that teeth of small gear of
gear assembly (390) mesh with teeth of jackscrew (450) and teeth of large gear of gear
assembly (390) mesh with teeth of small gear of gear assembly (380).
(15) Position rear gear plate (330) on moving tube housing (530). Use care to avoid dropping shim
washers (370B) from gear assembly (390), and shim washers (400 and 410), two thrust
washers (430) and thrust bearing (440) from rear gear plate (330).
CAUTION: LIGHTLY COAT THE GEAR ASSEMBLY TEETH WITH GREASE. EXCESS
AMOUNTS OF GREASE WILL BIND THE GEAR TRAIN.
(16) Apply grease to gear assemblies (380 and 390) and jackscrew (450) gear teeth.
(17) Secure rear gear plate (330) to moving tube housing (530) with three screws (340).
H. Position connector block (310) on rear gear plate (330).
I. Install connector (270) as follows:
(1) Carefully position connector (270) on connector block (310). Ensure wires are not trapped,
kinked or pinched.
(2) Install terminal (260) on screw (280).
(3) Use two screws (280), screw (290), and screw (300) to secure connector (270) to connector
block (310) and rear gear plate (330). Ensure terminal (260) is properly oriented. After final
tightening, install lock wire, MS20995-N32, on two screws (280), screw (290), and screw (300).
J. Make electrical connections as follows:
Assembly
Page 704
21-25-03 Jan 23/2004
SYLC51836 SERIES
(1) Attach leads from connector (270) according to location tags attached during disassembly.
Allow approximately ½” (12,7mm) of slack in connector leads to permit removal of rear gear
plate (330) should it become necessary to re-shim jackscrew (450) to meet end play
specifications in Para. K(7).
WARNING: BEFORE ATTEMPTING ANY SOLDERING, PERSONNEL MUST BE FAMILIAR

WITH TYPICAL SOLDERING PROCEDURES FOR AIRPLANE ELECTRICAL AND
ELECTRONIC WIRING, INCLUDING WARNINGS AND CAUTIONS. WEAR EYE
PROTECTION AND AVOID BREATHING FUMES GENERATED BY SOLDERING
OR SOLVENTS. TO AVOID INGESTION OF POISONOUS LEAD OXIDE FROM
SOLDER, PERSONNEL MUST WASH HANDS BEFORE SMOKING OR EATING.
EYE PROTECTION IS REQUIRED. USE EXTREME CAUTION TO AVOID BEING
BURNED.
(2) Solder leads from connector (270) to low pass EMI filters (130, 500) as indicated on location
tags attached during disassembly. Remove tags.
(3) Attach motor (510) leads to extend limit switch S2 (140) and retract limit switch S1 (220) as
indicated on location tags attached during disassembly. Solder connections. Remove tags.
(4) Connect connector (270) leads to switch S3 as indicated on location tags attached during
disassembly. Solder connections. Remove tags.
(5) Attach remaining connector (270) leads to switches S1 and S2 as indicated on location tags
attached during disassembly.
(6) Attach wires from solder terminal (120) to switches S1 and S2 as indicated on location tags
attached during disassembly. Solder connections. Remove tags.
K. If required, install three adjusting screws (490B or 490C and 495A) in moving tube assembly (480)
as follows:

(1) Coat at least 30 percent of thread diameter of adjusting screws (490B or 490C and 495A) with
epoxy adhesive.

(2) Place a bead of epoxy adhesive on joining face of moving tube assembly (480).
(3) Install adjusting screws (490B or 490C and 495A). Ensure adjusting screw that contacts S3
switch actuator (160) is adjusted 0.01 to 0.02 in. (0,25 to 0,50 mm) farther out than adjusting
screw (490B or 490C) that contacts S2 switch actuator (200).
Assembly
Page 705
21-25-03 Jan 23/2004
SYLC51836 SERIES
CAUTION: HOLD ROD-END BEARING ASSEMBLY WHEN TIGHTENING JAM NUT TO
PREVENT DAMAGE TO THE MOVING TUBE ASSEMBLY.
(4) For SYLC51836 and SYLC51836-1, temporarily install rod-end bearing assembly (10) and jam
nut (20) on moving tube assembly (480).
(5) Perform electrical extend and retract performance tests per TESTING AND FAULT ISOLATION
section. Final set limit adjusting screws (490B or 490C and 495A) to meet extend and retract
limit specifications contained in test steps. Use care to not disturb adjusting screw (490B or
490C and 495A) settings until epoxy adhesive is cured.
(6) Perform NULL performance test per TESTING AND FAULT ISOLATION section. Final set limit
adjusting screw (490B or 490C and 495A) to meet indication limit specification contained in test
steps. Use care to not disturb adjusting screw (490B or 490C and 495A) settings until epoxy
adhesive is cured.
(7) Perform end play performance test of linear actuator per TESTING AND FAULT ISOLATION
section. Add or remove shim washers (400 and 410) as required to meet end play
specifications. Refer to DISASSEMBLY and ASSEMBLY paragraphs that pertain to gear train
alignment for shim addition and deletion procedural details.
CAUTION: HOLD END BODY ASSEMBLY WHEN LOOSENING JAM NUT TO PREVENT
(8) For SYLC51836 and SYLC51836-1, remove rod-end bearing assembly (10) and jam nut (20)
from moving tube assembly (480).
L. Install cover (30) as follows:
WARNING: SILICONE ADHESIVE SEALANT IS TOXIC. USE IN WELL-VENTILATED AREA.

PREVENT EYE AND SKIN CONTACT AND DO NOT BREATHE VAPORS. IN
CASE OF EYE CONTACT, FLUSH WITH WATER AND SEEK MEDICAL
ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
CAUTION: DO NOT ALLOW SILICONE ADHESIVE SEALANT TO CONTACT THE

PREFORMED PACKING OR THE MOVING TUBE ASSEMBLY WHEN SEALING
THE COVER TO THE MOVING TUBE HOUSING. THIS COULD INTERFERE WITH
MOVEMENT OF THE MOVING TUBE ASSEMBLY.
(1) Install cover (30) on moving tube housing (530). Secure cover with two screws (40) and
lockwashers (50). Seal moving tube housing/cover interface with sealant. Remove excess
sealant with a clean lint-free cloth. Allow sealant to air dry for four hours.
CAUTION: HOLD END BODY ASSEMBLY WHEN TIGHTENING JAM NUT TO PREVENT
(2) For SYLC51836 and SYLC51836-1, install rod-end bearing assembly (10) and jam nut (20) on
moving tube assembly (480).
Assembly
Page 706
21-25-03 Jan 23/2004
SYLC51836 SERIES
3. Storage.
CAUTION: UNPACKAGED STORAGE IS NOT RECOMMENDED.
A. Pack linear actuator as follows:
(1) Wipe linear actuator with a clean cloth to remove dust, dirt and foreign material.
(2) Preserve linear actuator in accordance with MIL-P-116, Method 1-A-8.
(3) Wrap linear actuator in wrapping material and place in plastic bag.
B. Place cushion and dunnage material, desiccant and linear actuator in unit container, then seal with
masking tape.
C. Mark outside of unit container in accordance with MIL-STD-129. Also include overhaul date and
location.
Assembly
Page 707/708
21-25-03 Sep 14/01
SYLC51836 SERIES
FITS AND CLEARANCES
1. General.
A. Torque values used during assembly are supplied in Figure 801.
B. Refer to the IPL for an illustration of the linear actuator.
IPL FIGURE ITEM ITEM TORQUE

20 Jam nut 49 to 51 lb in. (5,5 to 5,7 Nm)
40 Screw 2.4 to 2.6 lb in. (0,27 to 0,30 Nm)
80/90 Screw/nut 4.8 to 5.3 lb in. (0,54 to 0,60 Nm)
130 Nut (supplied with component) 47 to 49 lb in. (5,3 to 5,5 Nm)
150, 190, 230 Screw 2.4 to 2.6 lb in. (0,27 to 0,30Nm)
Table of Torque Values

Figure 801
Fits and Clearances

Page 801/802
21-25-03 Sep 14/01
SYLC51836 SERIES
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. General.
A. Special tools, fixtures and equipment are listed in Figure 901. Equivalent substitutes may be used
for the items listed. Equipment items that require a specified calibration must have a current
certification approval.
B. Manufacture running test fixture per Figure 902.
C. Manufacture test cable per Figure 903 or 904.
D. Manufacture test bar per Figure 906 or 907.
vendors.

DC Ammeter 0-1.0 Adc, 0.5% full scale accuracy Commercially available
DC Power Supply 0-30 Vdc, 5 amp min., DC power source Commercially available
DC Voltmeter 0-30 Vdc, 0.5% full scale accuracy Commercially available
Dial Indicator 2.000 in. (50,8 mm) travel, 0.5% full Commercially available
scale accuracy
Fixture NYLZ51513 Running test fixture Locally manufactured or
Smiths Aerospace – Rockford
(V05624)
Fixture PYLZ51196 Hydraulic test fixture Smiths Aerospace – Rockford
(V05624)
Force Gage DPPH-250 Force gage indicator, factory Chatillon, John and Sons, Inc.
specification (V11710)
Insulation Resistance Factory specifications, insulation LEM Instruments, Inc.
Tester Model Unilap resistance tester (V1JHT9)
ISO-X
Model 87 (2) Digital multimeter (DMM), factory Fluke Electronics Corp.
specifications (V89536)
Test Cable Connect linear actuator to running test Locally manufactured
fixture
Special Tools, Fixtures and Equipment (Sheet 1 of 2)
Figure 901
Special Tools, Fixtures and Equipment

Page 901
21-25-03 Jan 23/2004
SYLC51836 SERIES
Test Bar Hydraulic test fixture setup Locally manufactured or
PYLZ-53380 or Smiths Aerospace – Rockford
PYLZ-53381 (V05624)
Timer 0.2 second accuracy per operation, Commercially available
electric timer
Special Tools, Fixtures and Equipment (Sheet 2 of 2)

Figure 901
Running Test Fixture, NYLZ51513

Figure 902

Page 902
21-25-03 Jan 23/2004
SYLC51836 SERIES
Test Cable Schematic For SYLC51836-1

Figure 903
APPROXIMATELY
3 FT (0,9M)
TO
A 1 CW JACK
B 2 CCW JACK
LINEAR C 3 COM JACK
ACTUATOR D 4 +28 VDC JACK
CONNECTOR E 5 L1(+) JACK
F 6 L2(+) JACK
AWG 22 GAUGE
INSULATED WIRES
CONNECTOR
P/N 26FB98JN OR 26FB98SN
Test Cable Schematic For SYLC51836 and SYLC51836-10

Figure 904

Page 903
21-25-03 Sep 14/01
SYLC51836 SERIES
LOAD DIRECTION DIAL
LEVER INDICATOR
HYDRAULIC
CYLINDER LINEAR
HYDRAULIC FORCE
ACTUATOR GAUGE
POWER PACK
COMPRESSION TENSION
51836905.CDR
TEST BAR
Hydraulic Test Fixture, PYLZ51196

Figure 905
1.00 (25.4)
0.255
0.245 ( 6,223
6,477
)
7.190
+0.0005
-0.0005(182.626
+0.0127
)
-0.0127
MATERIAL - 0.50 (12.7) STEEL
0.2505
0.2500 ( 6,3500
6,3627
) INSIDE DIAMETER
HARDENED BUSHINGS (2)
53046007a.CDR
1.00 (25.4)
Dimensions in inches (millimeters)
Test Bar, PYLZ-53380

Figure 906

Page 904
21-25-03 Jan 23/2004
SYLC51836 SERIES
(
0.2505 6.362
)
0.2500 6.350 INSIDE DIAMETER
HARDENED BUSHING
0.245–0.255
(6,22–6,48)
0.120–0.130
(3,05–3,30)
0.745–0.755
(18,92–19,18)
0.495–0.505 RADIUS
(12,57–12,83)
0.245–0.255
(6,22–6,48)
6.2595–6.2605
(158,99–159,02)
0.3125–24 THREAD
0.75 MIN. DEEP 6.7595–6.7605
(19,05 MIN.) (171,69–171,72)
0.495–0.505 MATERIAL - 0.50 SQUARE STEEL

(12,57–12,83)
Dimensions in inches (millimeters) 51836007.CDR
Test Bar, PYLZ-53381

Figure 907

Page 905/906
21-25-03 Jan 23/2004
SYLC51836 SERIES
ILLUSTRATED PARTS LIST
1. Introduction.
A. Purpose.
The Illustrated Parts List (IPL) provides a breakdown of assemblies and detailed parts composing
the equipment. The IPL includes the following sections: Introduction, Manufacturers Numbered Part
Cross Reference Index and Detailed Parts List.
B. Figure and Item Number Column.
The item numbers shown in the Detailed Parts List correspond to item numbers appearing on the
exploded-view illustration. To find a part number when the part number is unknown, locate the part
on the illustration and note the item number. Locate the item number on the Detailed Parts List.
The part number will be shown on the same line. Item numbers preceded by a dash (-) in the
Detailed Parts List are not illustrated.
C. Part Number Column.
The PART NUMBER column shows the Smiths Aerospace, Rockford, vendor or Government
standard part number of each item in the list. It matches the part number convention of ATA 200.
D. Airline Part Number Column.
The AIRLINE PART NUMBER column is left blank for airline use.
E. Nomenclature Column.
The NOMENCLATURE column shows the title and modifiers of a part in accordance with
manufacturer's drawing title and other data characteristics where applicable. Metric equivalent
dimensions are shown in parentheses.
F. Effectivity Code Column.
When more than one configuration of the basic part number is covered in the Detailed Parts List, an
Effectivity Code will be used to show the difference in parts within the various configurations.
G. Units Per Assembly Column.
The numbers appearing in the Units Per Assembly column are the total quantity of the listed part
required in its immediate assembly. Other possible conditions related to the status of the listed part
are indicated in this column by abbreviations noted below:
AR = As Required
ALT = Alternate
NP = Non-Procurable
RF = Reference
Illustrated Parts List

Page 1001
21-25-03 Sep 14/01
SYLC51836 SERIES
H. Attaching Parts.
Attaching parts for any assembly or subassembly are listed in the same column immediately
beneath the item to be attached and precede any detailed parts of that item. In general, attaching
parts are listed only for those items that are frequently removed. The symbol *** is used to denote
the end of the attaching parts and the continuation of the assembly listing.
2. Model/Series/Type of End Item.
The items covered are linear actuator assembly, PNs SYLC51836, SYLC51836-1, and SYLC51836-10
(1, IPL Figure 1).
3. Vendor Code.
The names and codes of all vendors supplying detailed parts are shown below:
vendors.
vendor CAGE codes and addresses: www.dlis.dla.mil/bincs/default.asp.
VENDOR CODE VENDOR’S NAME

V03508 General Electric Co.
Semi-Conductor Products Dept.
V05624 Smiths Aerospace – Rockford
V13675 Wems, Inc.
V40920 MBP Corp.
V50294 New Hampshire Ball Bearings, Inc.

Precision Division
V60380 The Torrington Co.

Needle Bearings Div.
V81168 Richardson Co.

Hercules Product Div.
V91929 Honeywell Sensing and Control

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SYLC51836 SERIES
4. Manufacturer Numbered Part Cross-Reference Table.
This table is provided to cross-reference manufacturer part numbers to standard part numbers.
Manufacturer Equivalent Manufacturer Equivalent

Part No. Standard Part Part No. Standard Part
AE24-29 MS3470L10-6P JYRF226-11 MS35190-211
CYRD160 MS35333-35 JYRF230-12 MS35265-12
CYRD188 MS35338-40 HYRF37-25 MS21209-C0415
JYRF234 -1 MS35206-201 HYRF37-3 MS21209-C0410
JYRF226-29 MS35190-229

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SYLC51836 SERIES
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Page 1004
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SYLC51836 SERIES
90
120 100
100
130
130
70
150
140
160
170
SEE SHEET 2
250
240
220
30
230
210
180 50
40
200
190
60
110
20
10
518361007.CDR
80
Linear Actuator, SYLC51836 (Sheet 1 of 2)

IPL Figure 1

Page 1005
21-25-03 Sep 14/01
SYLC51836 SERIES
300
290
320
310
280
260 350
270 350
330
360
340
370
380
360
370
430
390 360
440 370B
430
400
410
420
450
430
440
430
520
500
460
510
540
530
480
495 490
470
518361008.CDR
Linear Actuator, SYLC51836 (Sheet 2 of 2)

IPL Figure 1

Page 1006
21-25-03 Sep 14/01
SYLC51836 SERIES
AIRLINE UNITS
FIG. PART NOMENCLATURE EFF PER
ITEM PART NUMBER NUMBER 1 2 3 4 5 6 7 CODE ASSY
1-
-1 SYLC51836 LINEAR ACTUATOR ASSEMBLY A 1
-1A SYLC51836-1 LINEAR ACTUATOR ASSEMBLY B 1
-1B SYLC51836-10 LINEAR ACTUATOR ASSEMBLY C 1
10 SYLC2001 . ROD END ASSEMBLY A, B 1
20 AB10-19 . NUT, JAM A, B 1
30 SYLC1543 . COVER 1
ATTACHING PARTS
40 MS35206-201 . SCREW (JYRF234-1 - V05624) 2
50 MS35333-35 . WASHER, LOCK, INTERNAL 2
TOOTH (CYRD160 - V05624)
***
60 NYRZ1-12 . NAMEPLATE A 1
60 NYRZ1-12 DELETED B, C
70 SYLC1487 . CLIP, FILTER SUPPORT 1
ATTACHING PARTS
80 MS35190-229 . SCREW (JYRF226-29 - V05624) 2
90 DYRF447 . NUT 2
100 MS35338-40 . WASHER, LOCK, SPRING 2
(CYRD188 - V05624)
***
110 SYLC1477 . STOP 1
120 FYRE12 . TERMINAL 1
130 FA103HAA . FILTER, EMI, LOW PASS 1
(WITH NUT) (V13675)
(TPN FA-103-HAA)
(E11-22-1 – V05624)
140 91SX39T . SWITCH, SENSITIVE SPDT 1
UNSEALED (V91929)
(TPN 91SX39-T)
(E23-195-2 - V05624)
ATTACHING PARTS
150 JYRF404 . SCREW 2
***
160 E23-196 . ACTUATOR, SWITCH 1
- Item Not Illustrated

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SYLC51836 SERIES
AIRLINE UNITS
1-
170 JX10131 . INSULATOR, SWITCH (V91929) 1
(TPN JX10131)
(NYLC6 - V05624)
180 91SX39T2 . SWITCH, SENSITIVE SPDT A, C 1
UNSEALED (V91929)
(TPN 91SX39-T2)
(E23-195-4 - V05624)
-180A 93SX39T . SWITCH, SENSITIVE SPDT B 1
UNSEALED (V91929)
(TPN 93SX39-T)
(E23-195-7 - V05624)
ATTACHING PARTS
***
(NYLC6 - V05624)
220 91SX39T . SWITCH, SENSITIVE SPDT 1
UNSEALED (V91929)
(TPN 91SX39-T)
(E23-195-2 - V05624)
ATTACHING PARTS
***
(NYLC6 - V05624)
260 AYLZ43 . TERMINAL 1
270 MS3470L10-6P . CONNECTOR (AE24-29 – V05624) 1
ATTACHING PARTS
280 JYRF277 . SCREW, MACHINE FILLISTER 2
290 BYRF534 . SCREW, MACHINE, FILLISTER 1
300 MS35265-12 . SCREW (JYRF230-12 – V05624) 1
***

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21-25-03 Sep 14/01
SYLC51836 SERIES
AIRLINE UNITS
1-
310 SYLC1535 . BLOCK, CONNECTOR 1
320 MS21209C0415 . . INSERT, HELICOIL 1
(HYRF37-25 – V05624)
330 SYLC1532 . PLATE, REAR GEAR 1
ATTACHING PARTS
340 BYRF298 . SCREW MACHINE, FILLISTER 3
***
(TPN MS21209-C0415)
(HYRF37-25 - V05624)
360 S418C3P15L02 . BEARING (V40920) 4
(TPN S418C3P15L02)
(P1-142 - V05624)
370 CYRD311-1 DELETED
-370A CYRD311-2 DELETED
370B CYRD311-3 . WASHER, SHIM 1
-370C CYRD311-4 DELETED
-370D CYRD311-5 DELETED
380 SYLC1536 . GEAR ASSEMBLY 1
390 SYLC1537 . GEAR ASSEMBLY 1
400 CYRD500 . WASHER, SHIM AR
410 CYRD501 . WASHER, SHIM AR
420 CYRD815 DELETED
430 SYLC2145 . WASHER, THRUST 4
440 NTA411 . BEARING, THRUST (V60380) 2
(TPN NTA-411)
(SYLC790 - V05624)
450 SYLC1542 . JACKSCREW 1
460 R34WIIHA3 . BEARING (V50294) 1
(TPN R-34WIIHA3)
(CYRB165 - V05624)
470 1820-7 . PACKING, PREFORMED (V81168) 1
(6-348- V05624)

Page 1009
21-25-03 Jan 23/2004
SYLC51836 SERIES
AIRLINE UNITS
1-
480 SYLC1546 . MOVING TUBE ASSEMBLY 1
490 SYLC1426-1 . . SCREW, ADJUSTING (SUPSD BY A 3
ITEM -490B)
-490A SYLC1426-1 . . SCREW, ADJUSTING (SUPSD BY B, C 2
ITEM -490C)
-490B SYLC-2220-3 . . SCREW, ADJUSTING (SUPSDS A 3
ITEM 490)
-490C SYLC-2220-3 . . SCREW, ADJUSTING (SUPSDS B, C 2
ITEM 490A)
495 SYLC1426-3 . . SCREW, ADJUSTING (SUPSD BY B, C 1
ITEM -495A)
-495A SYLC-2220-3 . . SCREW, ADJUSTING (SUPSDS B, C 1
ITEM 495)
500 FA-103-HAA . FILTER, EMI, LOW PASS 1
(WITH NUT) (V13675)
(TPN FA-103-HAA)
(E11-22-1 – V05624)
510 KYLM43700-6 . MOTOR ASSEMBLY 1
ATTACHING PARTS
520 MS35190-211 . SCREW (TPN MS35190-211) 2
(JYRF226-11 – V05624)
***
530 SYLC1539 . HOUSING, MOVING TUBE 1
(TPN MS21209-C0410)
(HYRF37-3 - V05624)

Page 1010
21-25-03 Jan 23/2004

CMM 21-25 Linear Actuator

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CMM 21-25 Linear Actuator

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TO: HOLDERS OF LINEAR ACTUATOR ASSEMBLY SYLC 51836 SERIES COMPONENT

REVISION NO. 2 DATED FEBRUARY 18/2004

This is Revision 2 for the SYLC 51836 Component Maintenance Manual.

Title Revised to show latest revision. All Models

Record of Revised to include Revision 2 information. All Models

List of Effective Revised to indicate revised pages. All Models

Testing and Revised Figure 109 All Models

E-Mail: CS.support@smiths-aerospace.com E-Mail: admin@smithsind.com.au E-Mail: CSAsupport@smiths-aerospace.com

COMPONENT MAINTENANCE MANUAL

Uncontrolled when reproduced 21-25-03

WARNING: PERFORM SOLVENT CLEANING IN AN APPROVED CLEANING CABINET OR IN A WELL-

WARNING: SILICONE ADHESIVE SEALANT IS TOXIC. USE IN WELL-VENTILATED AREA. PREVENT

WARNING: THERMAL STRIPPERS SHOULD BE USED ONLY IN WELL-VENTILATED AREAS TO

WARNING: BEFORE ATTEMPTING ANY SOLDERING, PERSONNEL MUST BE FAMILIAR WITH

CAUTION: USE AN ISOLATED LOW-WATTAGE CONTROLLED HEAT SOLDERING IRON TO

CAUTION: UNPACKAGED STORAGE IS NOT RECOMMENDED.

REV. ISSUE DATE DATE INSERTED REV. ISSUE DATE INSERTED

TEMPORARY PAGE ISSUE INSERTED DATE INSERTED

Record of Temporary Revisions

SERVICE DATE PARTS ADDED OR

Service Bulletin List

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page 1 Jan 23/2004 Cleaning 401 Jan 23/2004

List of Effective Pages

DESCRIPTION AND OPERATION .................................................................................................................... 1

TESTING AND FAULT ISOLATION .............................................................................................................. 101

AUTOMATIC TEST REQUIREMENTS .......................................................................................................... 201

DISASSEMBLY .............................................................................................................................................. 301

CLEANING ..................................................................................................................................................... 401

CHECK ........................................................................................................................................................... 501

REPAIR .......................................................................................................................................................... 601

ASSEMBLY .................................................................................................................................................... 701

FITS AND CLEARANCES ............................................................................................................................. 801

SPECIAL TOOLS, FIXTURES AND EQUIPMENT ........................................................................................ 901

ILLUSTRATED PARTS LIST ....................................................................................................................... 1001

Smiths Aerospace - Rockford

The following abbreviations/symbols are used in this manual:

ABBREVIATION DEFINITION ABBREVIATION DEFINITION

Description and Operation

A. The moving tube extends as follows:

B. The moving tube retracts as follows:

Description and Operation

Linear Actuator Specifications:

Description and Operation

3. Pretest Checks and Setup.

(2) Do the operational checks listed paragraph 4.

(6) Do the operational checks listed in paragraph 4 to verify proper operation.

See the CHECK section.

Testing and Fault Isolation

ITEM / PART NO. SPECIFICATION / DESCRIPTION SOURCE

Tools and Test Equipment

Testing and Fault Isolation

Running Test Fixture, NYLZ51513

Test Cable Schematic For SYLC51836-1

Testing and Fault Isolation

Test Cable Schematic For SYLC51836 and SYLC51836-10

LOAD DIRECTION DIAL

Hydraulic Test Fixture, PYLZ51196

Testing and Fault Isolation

MATERIAL - 0.50 (12.7) STEEL

Dimensions in inches (millimeters)

0.495–0.505 MATERIAL - 0.50 SQUARE STEEL

Dimensions in inches (millimeters) 51836007.CDR

Testing and Fault Isolation