Model 500 Series Component Maintenance Manual (Rev 17)

24-50-01 (Rev 5)

THRUST REVERSER JUNCTION BOX - TESTING

1. Check Junction Box
A. Before performing this functional test, verify that pins L and N of connector J203 and pin L of connector J204 are correctly
wired, as indicated on the appropriate electrical wiring diagram. If the pins are not properly wired, correct before
proceeding with the functional test. Refer to Figure 602 for wires and jumpers, which must be checked and installed, if not
already installed.
B. Functional Test.
(1) Connect a 6587000-1 thrust reverser junction box tester to the junction box to be tested.
NOTE: Instructions for fabrication of 6587000-1 thrust reverser junction box tester are included in this
section.
NOTE: This test may be performed with the junction box installed in the airplane or may be performed
as a bench test. The sequence of steps is designed to simulate the operating sequence in a
functioning thrust reverser system.
(2) Set switches on the tester:
S1, S2 NORMAL
S3, S4 STOW
S5, S6 STOWED
S7, S8 AIR
S9, S10 STOWED/IN TRANSIT
S11 OFF
NOTE: The steps within this test must be performed sequentially. The test box switches must be reset
only as instructed during the functional test steps.
(3) Connect a source of 28.5 VDC, +0.5 or -0.5 VDC to the tester.
(4) Set switch S11 to LAMP TEST.
(a) Verify that all indicator lights on tester are illuminated.
(5) Set S11 to OFF.
(a) Verify that all indicator lights on tester are extinguished.
NOTE: Steps (6) through (10) check the left deploy circuit.
(6) Set switch S7 to GND.
(a) Verify that light L11 DEPLOY GND is illuminated.
(b) Verify that lights L13 M.W. GND and L14 M.W. GND are illuminated. (L13 and L14 should never be illuminated
when testing a 5538328-1 junction box.)
NOTE: If L11 is not illuminated, check for open diode D183 or D191 or faulty transistor Q12. If L13
and L14 are not illuminated (-8, -16 junction boxes only), check for open diode D191 or
D469.
(7) Set switch S3 to DEPLOY.
(a) Verify that lights L3 DEPLOY, L5 ISOLATION VALVE, L7 CENTER VALVE 1, L9 CENTER VALVE 3, L10
CENTER VALVE 2, L11 DEPLOY GND, L13 M.W. GND and L14 M.W. GND are illuminated.
NOTE: If L3 is not illuminated, the jumper between pins F and T of connector J203 is open. If L5 is
not illuminated, diode D169 is open. If L7, L9 and L10 are not illuminated, check for open
diode D169 or D178. If L7 and L9 are illuminated but L10 is not, check for open jumper
between diodes D178 and D180.
(8) Set switch S3 to STOW and switch S5 to DEPLOYED/IN TRANSIT.
(a) Verify that light L3 extinguishes and that light L1 STOW illuminates. All other lights remain as in step (7).
NOTE: If L1 is not illuminated, diode D167 is open. If L1 is illuminated but L5 is not illuminated,
diode D171 is open.

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

(9) Connect a 3 1/2 digit voltmeter to TP3(+) and TP1(-).

(10) Set switch S9 to DEPLOYED position and switch S3 to DEPLOY.
(a) Verify that light L1 extinguishes and light L3 illuminates.
(b) Verify that voltmeter momentarily reads 22.5 VDC, +1.5 or -1.5 VDC and then gradually drops to 6.8 volts within
one minute.
NOTE: If initial voltage is low or not present, check resistor R77, diode D229, capacitor C25 for
open or transistors Q5 or Q6 may be faulty.
NOTE: If voltage does not drop, verify the electrical integrity of transistor Q5.
NOTE: Step (11) checks the left emergency stow circuit.
(11) Set switch S1 to EMER STOW, switch S3 to STOW, switch S5 to STOWED and switch S9 to STOWED/IN
TRANSIT.
(a) Verify that light L1 illuminates and light L3 extinguishes.
NOTE: If L5 is not illuminated, diode D171 is open. If L5, L7, L9 and L10 are not illuminated, diode
D171 and D179 are open. Also check diode D178 for open.
(b) Verify that voltage across TP3(+) and TP1(-) is O VDC.
(12) Set switch S1 to NORMAL and switch S7 to AIR.
(a) Verify that all test box lights extinguish.
NOTE: Steps (13) through (17) check the right deploy circuit.
(13) Set switch S8 to GND.
(a) Verify that light L12 DEPLOY GND is illuminated.
(b) Verify that lights L13 M.W. GND and L14 M.W. GND are illuminated. (L13 and L14 should never be illuminated
when testing a 5538328-1 junction box.)
NOTE: If L12 is not illuminated, check for open diode D182 or D190 or faulty transistor Q11. If L13
and L14 are not illuminated (-8, -16 junction boxes only), check for open diode D190 or
D469.
(14) Set switch S4 to DEPLOY.
(a) Verify that lights L4 DEPLOY, L6 ISOLATION VALVE, L7 CENTER VALVE 1, L9 CENTER VALVE 3, L10
CENTER VALVE 2, L12 DEPLOY GND, L13 M.W. GND and L14 M.W. GND are illuminated.
NOTE: If L4 is not illuminated, the jumper between pins F and T of connector J204 is open. If L6 is
not illuminated, diode D170 is open. If L7, L9 and L10 are not illuminated, check for open
diode D170 or D180. If L10 is illuminated but L7 and L9 are not, check for open jumper
between diodes D178 and D180.
(15) Set switch S4 to STOW and switch S6 to IN TRANSIT/DEPLOYED.
(a) Verify that light L4 extinguishes and that light L2 STOW illuminates. All other lights remain as in step (14).
NOTE: If L2 is not illuminated, diode D168 is open. If L2 is illuminated but L6 is not illuminated,
diode D172 is open.
(16) Connect a 3 1/2 digit voltmeter to TP4(+) and TP2(-).
(17) Set switch S10 to DEPLOYED position and switch S3 to DEPLOY.
(a) Verify that light L2 extinguishes and light L4 illuminates.
(b) Verify that voltmeter reads 22.5 VDC, +1.5 or -1.5 VDC, and then gradually drops to 6.8 volts within one minute.
NOTE: If initial voltage is low or not present, check resistor R76, diode D230 or capacitor C26 for
open, or transistors Q7 or Q8 may be faulty.
NOTE: If voltage does not drop, verify the electrical integrity of transistor Q7.
NOTE: Step 18 checks the right emergency stow circuit.
(18) Set switch S2 to EMER STOW, switch S4 to STOW, switch S6 to STOWED and switch S10 to STOWED/IN
TRANSIT.
(a) Verify that light L2 illuminates and light L4 extinguishes.

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

NOTE: If L6 is not illuminated, diode D172 is open. If L6, L7, L9 and L10 are not illuminated, diode
D172 and D180 are open. Also check diode D181 for open.
(b) Verify that voltage across TP4(+) and TP2(-) is O VDC.
(19) Set switch S2 to NORMAL and switch S8 to AIR.
(a) Verify that all test box lights extinguish.
(20) Remove external power from thrust reverser junction box tester.
(21) Disconnect thrust reverser junction box tester from thrust reverser junction box.
(22) Check the isolation diodes on the thrust reverser printed circuit board for open by connecting the positive lead of a
voltmeter to pin R of either P203 or P204 and successively applying the negative voltmeter terminal to the pins listed
in Table 101.
Table 101. Checking Isolation Diodes
P203 pin N diode D177
P203 pin E diode D173
P203 pin F diode D165
P203 pin D diode D163
P204 pin F diode D166 (NOTE)
P204 pin E diode D174 (NOTE)
P204 pin D diode D164 (NOTE)
NOTE: Varister on 5538328-8, 5538378-16 may be Varister on 5538328-1.
(23) After completion of and passing of the functional test, attach a tag to the thrust reverser junction box indicating that the
box conforms to the requirements of the Components Maintenance Manual.
C. Fabrication of 6587000-1 Thrust Reverser Junction Box Tester. Refer to Figure 101.
(1) Using the drawings and parts list provided, fabricate a thrust reverser junction box tester.
(2) Parts List for the 6587000-1 Thrust Reverser Junction Box Tester.
TERMINOLOGY PART NUMBER QUANTITY FEDERAL SUPPLY
REQUIRED CODE
Binding Post 1464-102 1 83330
Binding Post 1464-103 3 83330
Binding Post 1464-107 2 83330
Resistor F204 or 2 44655
VPR-20-14-10 or 12697
HL-20-10 91637
Light 922-404X-410RT or 13 75915
5131-038-304 71744
RED or 162-971 72619
Box AC-406BPA 112611 71218
Plate 15931N4006 71218
Diode MST-205N or 95146
Switch 7201-S-Y-Z-Q or 09353
JMT-223 15605
Terminal Board 15299 2 91833
Connector MS3126F14-19SY 1 11139
Connector MS3126F14- 19SN 1 11139
Strain Relief SL13 1 8U767

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Backshell GTR00V14B 2 06324

Wire 20 Gage MIL-W-81044/12-20-9 200 Feet
Screw MS35206-327 12
Screw MS35206-217 4
Spacer NAS43DD1-8 12
Nut MS21042-04 4
Nut MS21042-06 12
D. Manufacturer’s Federal Supply Codes and addresses for fabrication of Thrust Reverser Junction Box Tester.
06323 GLENAIR 72619 AMPEREX ELECTRIC CORP.
1211 Air Way 203 Harrison Pl.
Glendale, CA 91201 Brooklyn, NY
09353 C & K COMPONENTS, INC. 75915 TRACOR LITTELFUSE INC.
15 Riverdale Ave. 800 E. NW Highway
Newton, MA 02158 Des Plaines, IL 60016
11139 DEUTSCH CO. 83330 KULKA SMITH INC.
700 S. Hathaway 1913 Atlantic Ave.
Municipal Airport Manasquan, NJ 08736
Banning, CA 92220
12697 CLAROSTAT MANUFACTURING CO. 91637 DALE ELECTRONICS INC.
Lower Washington Street P.O. Box 609
Dover, NH 03820 Columbus, NE 68601
15605 EATON CORP. 91833 KEYSTONE ELECTRONICS CORP.
4201 N. 27th St. 49 Bleecker St.
Milwaukee, WI 53216 New York, NY 10012
44655 OHMITE MANUFACTURING CO. 95146 ALCO ELECTRIC PRODUCTS, INC.
3601 W. Howard St. 1551 Osgood St.
Skokee, IL 60076 North Andover, MA 01845
71218 BUD INDUSTRIES, INC. 8U767 OLFLEX WIRE AND CABLE, INC.
4605 E. 355th St. 30 Plymouth Street
Willoughby, OH 44094 Fairfield, NJ 07006
71744 GENERAL INSTRUMENT CORP. LAMP
DIV.
4433 N. Ravenswood Ave.
Chicago, IL 60640

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Figure 101 : Sheet 1 : Fabrication of Thrust Reverser Junction Box Tester

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Figure 101 : Sheet 2 : Fabrication of Thrust Reverser Junction Box Tester

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Figure 101 : Sheet 3 : Fabrication of Thrust Reverser Junction Box Tester

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Figure 101 : Sheet 4 : Fabrication of Thrust Reverser Junction Box Tester

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Figure 101 : Sheet 5 : Fabrication of Thrust Reverser Junction Box Tester

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Figure 101 : Sheet 6 : Fabrication of Thrust Reverser Junction Box Tester

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 Model 500 Series Component Maintenance Manual (Rev 17)
24-50-01 (Rev 5)

Figure 601 : Sheet 1 : Thrust Reverser Junction Box Printed Circuit Board Components Immobilization

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