Drain and Refill Flap Actuator Assemblies with Semi-fluid

TASK 12-13-27-612-005-A
Drain and Refill Flap Actuator Assemblies with Semi-fluid

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

WARNING: MAKE SURE THAT THE GROUND SAFETY-LOCKS ARE IN POSITION ON THE LANDING GEAR. THIS WILL PREVENT UNWANTED MOVEMENT OF THE LANDING GEAR, AND THUS POSSIBLE INJURY TO PERSONS AND DAMAGE TO THE AIRCRAFT AND/OR EQUIPMENT.

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

CAUTION: BE CAREFUL WHEN YOU DO MAINTENANCE TASKS ON THE WING TRAILING EDGE:

DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE RACEWAYS.
DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE INSTALLATIONS.
MAKE SURE THAT THE ELECTRICAL CABLES ARE INSTALLED CORRECTLY. INCORRECT INSTALLATION CAN CAUSE DAMAGE.

ZONE: 147
ZONE: 148
ZONE: 573
ZONE: 575
ZONE: 673
ZONE: 675
FIN: 6205CM ** ON A/C NOT FOR ALL
FIN: 6211CM ** ON A/C NOT FOR ALL
FIN: 6221CM ** ON A/C NOT FOR ALL
FIN: 6233CM ** ON A/C NOT FOR ALL
FIN: 6255CM ** ON A/C NOT FOR ALL
FIN: 6261CM ** ON A/C NOT FOR ALL
FIN: 6271CM ** ON A/C NOT FOR ALL
FIN: 6283CM ** ON A/C NOT FOR ALL

1. Reason for the Job
Refer to the MPD TASK: 275449-06
DRAIN AND REFILL FLAP ACTUATOR ASSEMBLIES WITH SEMI-FLUID

NOTE: This procedure is done in two steps:

step one fills the actuator with clean semi-fluid
step two removes unwanted semi-fluid from the actuator.

2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	SAFETY BARRIER(S)
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 4.4 and 3.6 m.N (38.94 and 31.86 lbf.in )
No specific	Torque wrench: range to between 6.6 and 5.4 m.N (58.41 and 47.79 lbf.in )
98D27604000000	1	COLLAR-SAFETY, SPOILER
98D27604004000	1	COLLAR SAFETY SPOILER
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION
A663160	1	REPLENISHMENT KIT
FOR [6205CM] (FLAP ACTUATOR 1)
FOR [6255CM] (FLAP ACTUATOR 1)
No specific	1	ACCESS PLATFORM 1M (3 FT)-ADJUSTABLE
460005835	1	SLEEVE - GROUND LOCK
FOR [6211CM] (FLAP ACTUATOR 2)
FOR [6261CM] (FLAP ACTUATOR 2)
No specific	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
FOR [6221CM] (FLAP ACTUATOR 3)
FOR [6233CM] (FLAP ACTUATOR 4)
FOR [6271CM] (FLAP ACTUATOR 3)
FOR [6283CM] (FLAP ACTUATOR 4)
No specific	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03GDB1)	Synthetic Oil base Grease-Gearboxes or Rotary actuator Lithium Thickened Semi-fluid -
(Material No.06LCG9)	Non Hardening Jointing Putty-Medium Temp. Area - -
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
147	MAIN GEAR WELL AND HYDRAULIC COMPARTMENT
148	MAIN GEAR WELL AND HYDRAULIC COMPARTMENT
573	FIXED STRUCT FROM STA 1800 TO STA 4666
575	AFT OUTBD SE OF WING AND TE FIXED STRUCT
673	FIXED STRUCT FROM STA 1800 TO STA 4666
675	AFT OUTBD SE OF WING AND TE FIXED STRUCT
FOR [6205CM] (FLAP ACTUATOR 1)
FOR [6255CM] (FLAP ACTUATOR 1)
734, 744
FOR [6211CM] (FLAP ACTUATOR 2)
573AB
FOR [6221CM] (FLAP ACTUATOR 3)
575BB
FOR [6233CM] (FLAP ACTUATOR 4)
575FB
FOR [6261CM] (FLAP ACTUATOR 2)
673AB
FOR [6271CM] (FLAP ACTUATOR 3)
675BB
FOR [6283CM] (FLAP ACTUATOR 4)
675FB

D. Referenced Information

REFERENCE	DESIGNATION
TASK 27-00-00-080-002-A	Removal of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
TASK 27-50-00-866-008-A	Extension of the Flaps on the Ground
TASK 27-50-00-866-008-A-01	Extension of the Flaps/Slats on the Ground
TASK 27-50-00-866-009-A	Retraction of the Flaps on the Ground
TASK 27-50-00-866-009-A-01	Retraction of the Flaps/Slats on the Ground
TASK 27-50-00-866-011-A	Manual Extension of the Flaps
TASK 27-50-00-866-012-A	Manual Retraction of the Flaps
TASK 27-60-00-866-002-A	Extension-Retraction of the Spoilers for Maintenance
Flap Actuator - Track 1 ** ON A/C NOT FOR ALL
Flap Actuator - Track 1 ** ON A/C NOT FOR ALL
Flap Actuators - Tracks 2 thru 4
FOR [6205CM] (FLAP ACTUATOR 1)
FOR [6255CM] (FLAP ACTUATOR 1)
TASK 32-12-00-010-001-A	Open the Main Gear Doors for Access
TASK 32-12-00-410-001-A	Close the Main Gear Doors after Access
FOR [6211CM] (FLAP ACTUATOR 2)
TASK 57-51-37-000-002-A	Removal of the Access Panels 571AB(671AB), 573AB(673AB), 573BB(673BB), 573CB(673CB), 573EB(673EB)
TASK 57-51-37-400-002-A	Installation of the Access Panels 571AB(671AB), 573AB(673AB), 573BB(673BB), 573CB(673CB), 573EB(673EB)
FOR [6221CM] (FLAP ACTUATOR 3)
TASK 57-51-37-000-004-A	Removal of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
TASK 57-51-37-400-004-A	Installation of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
FOR [6233CM] (FLAP ACTUATOR 4)
TASK 57-51-37-000-004-A	Removal of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
TASK 57-51-37-400-004-A	Installation of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
FOR [6261CM] (FLAP ACTUATOR 2)
TASK 57-51-37-000-002-A	Removal of the Access Panels 571AB(671AB), 573AB(673AB), 573BB(673BB), 573CB(673CB), 573EB(673EB)
TASK 57-51-37-400-002-A	Installation of the Access Panels 571AB(671AB), 573AB(673AB), 573BB(673BB), 573CB(673CB), 573EB(673EB)
FOR [6271CM] (FLAP ACTUATOR 3)
TASK 57-51-37-000-004-A	Removal of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
TASK 57-51-37-400-004-A	Installation of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
FOR [6283CM] (FLAP ACTUATOR 4)
TASK 57-51-37-000-004-A	Removal of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
TASK 57-51-37-400-004-A	Installation of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)

3. Job Set-up
Subtask 12-13-27-941-056-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) In the cockpit, put a WARNING NOTICE(S) in position to tell persons not to operate the flight controls.
(2) Put a WARNING NOTICE(S) in position to tell persons not to operate the landing gear doors.
(3) Put the SAFETY BARRIER(S) in position.

Subtask 12-13-27-860-054-A ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration

WARNING: MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS SURFACES ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Extend the flaps fully (Ref. AMM TASK 27-50-00-866-008).
(2) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is in position on the flap/slat control lever in the cockpit.
(3) Extend the spoilers 1 thru 5 (Ref. AMM TASK 27-60-00-866-002).
(4) Make sure that a 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER is installed on each spoiler servo-control.

Subtask 12-13-27-865-059-A ** ON A/C NOT FOR ALL

C. Open, safety and tag this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B07
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
** ON A/C NOT FOR ALL
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 12-13-27-010-057-A ** ON A/C NOT FOR ALL

D. Get Access
(1) FOR [6205CM] (FLAP ACTUATOR 1), [6255CM] (FLAP ACTUATOR 1)
(a) Open applicable MLG door(s) 734 and/or 744 (Ref. AMM TASK 32-12-00-010-001).
(b) Make sure that the 460005835 SLEEVE - GROUND LOCK is installed on the applicable MLG door actuating-cylinder.
(c) Put the ACCESS PLATFORM 1M (3 FT)-ADJUSTABLE in position below the applicable MLG bay.
(2) FOR [6211CM] (FLAP ACTUATOR 2), [6261CM] (FLAP ACTUATOR 2)
(a) Put the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE in position below zone 573 (673).
(b) FOR [6211CM] (FLAP ACTUATOR 2)
Remove access panel 573AB (Ref. AMM TASK 57-51-37-000-002).
(c) FOR [6261CM] (FLAP ACTUATOR 2)
Remove access panel 673AB (Ref. AMM TASK 57-51-37-000-002).
(3) FOR [6221CM] (FLAP ACTUATOR 3), [6271CM] (FLAP ACTUATOR 3), [6233CM] (FLAP ACTUATOR 4), [6283CM] (FLAP ACTUATOR 4)
(a) Put the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE in position below zone 575 (675).
(b) FOR [6221CM] (FLAP ACTUATOR 3)
Remove access panel 575BB (Ref. AMM TASK 57-51-37-000-004).
(c) FOR [6271CM] (FLAP ACTUATOR 3)
Remove access panel 675BB (Ref. AMM TASK 57-51-37-000-004).
(d) FOR [6233CM] (FLAP ACTUATOR 4)
Remove access panel 575FB (Ref. AMM TASK 57-51-37-000-004).
(e) FOR [6283CM] (FLAP ACTUATOR 4)
Remove access panel 675FB (Ref. AMM TASK 57-51-37-000-004).

4. Procedure

CAUTION: DO NOT GET SEMI-FLUID LUBRICANT ON PLASTIC OR RUBBER MATERIALS. SEMI-FLUID LUBRICANT CAN CAUSE DAMAGE TO THE SURFACE. REMOVE UNWANTED SEMI-FLUID LUBRICANT WITH A LINT FREE CLOTH.

CAUTION: BE CAREFUL WHEN YOU DO MAINTENANCE TASKS ON THE WING TRAILING EDGE:

DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE RACEWAYS.
DO NOT CAUSE DAMAGE TO THE ELECTRICAL CABLE INSTALLATIONS.
MAKE SURE THAT THE ELECTRICAL CABLES ARE INSTALLED CORRECTLY. INCORRECT INSTALLATION CAN CAUSE DAMAGE.

Subtask 12-13-27-612-061-A ** ON A/C NOT FOR ALL

A. Drain and Fill the Flap Actuator Assemblies

Flap Actuator - Track 1 ** ON A/C NOT FOR ALL

Flap Actuators - Tracks 2 thru 4 ** ON A/C NOT FOR ALL

(1) Fill flap actuator No. 1 6205CM (6255CM) with the clean Synthetic Oil base Grease-Gearboxes or Rotary actuator Lithium Thickened Semi-fluid - (Material No.03GDB1) as follows:
(a) Use a Textile-Lint free Cotton - (Material No.14SBA1) made moist with the Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean the area around the vent plug (1) and the drain plug (2).
(b) Remove the vent plug (1) from the flap actuator.
(c) Remove the drain plug (2) from the flap actuator.

NOTE: The drain plug (2) is at the bottom of the actuator.

(d) Connect the A663160 REPLENISHMENT KIT to fill the flap actuator, as follows:
1 Install vent plug adaptor 3/8 UNF (A663159) in the vent plug hole of the flap actuator.
2 Install drain plug adaptor 3/8 UNF (A663159) in the drain plug hole of the flap actuator.
3 Assemble the semi-fluid pump (A663130/3) to the semi-fluid container (A663130/7).
4 Connect the supply hose from the semi-fluid pump to the vent plug adaptor.
5 Assemble the waste lid (A663130/5) to the used fluid container (A663130/6).
6 Connect the waste hose from the waste lid to the drain plug adaptor.
(e) Operate the semi-fluid pump and slowly fill the flap actuator with the clean Synthetic Oil base Grease-Gearboxes or Rotary actuator Lithium Thickened Semi-fluid - (Material No.03GDB1) . Operate the pump handle through its full travel until clean semi-fluid flows from the drain hose.
(f) Disconnect the supply hose from the vent plug adaptor.
(g) Remove the vent plug adaptor from the flap actuator.
(h) Disconnect the waste hose from the drain plug adaptor.
(i) Remove the drain plug adaptor from the flap actuator.
(j) Install the vent plug (1) in the flap actuator. Do not tighten it at this time.
(k) Install the drain plug (2) in the flap actuator. Do not tighten it at this time.
(2) Do the steps (1)(a) thru (1)(k) and fill:

Flap actuator No. 2 6211CM (6261CM)
Flap actuator No. 3 6221CM (6271CM)
Flap actuator No. 4 6233CM (6283CM).

Subtask 12-13-27-612-062-A ** ON A/C NOT FOR ALL

B. Removal of the Unwanted Semi-fluid from the Flap Actuator Assemblies

Flap Actuator - Track 1 ** ON A/C NOT FOR ALL

Flap Actuators - Tracks 2 thru 4 ** ON A/C NOT FOR ALL

(1) Operate the flaps through their full range of travel five times (Ref. AMM TASK 27-50-00-866-011) and (Ref. AMM TASK 27-50-00-866-012). After the last cycle, make sure that the flaps are in the fully extended position.
(2) Remove the unwanted semi-fluid from flap actuator No. 1 6205CM (6255CM) as follows:
(a) Remove the vent plug (1) from the flap actuator.
(b) Remove the drain plug (2) from the flap actuator.

NOTE: The drain plug (2) is at the bottom of the actuator.

(c) Install the vent plug adaptor 3/8 UNF (A663159) in the vent plug hole of the flap actuator.
(d) Install the drain plug adaptor 3/8 UNF (A663159) in the drain plug hole of the flap actuator.
(e) Connect the waste hose from the waste lid (A663130/5) to the drain plug adaptor.
(f) Connect the empty oil gun (A663130/4) to the vent plug adaptor.
(g) Operate the empty oil gun 15 times to put air into the flap actuator and to push the unwanted semi-fluid out. Make sure that you operate the oil gun handle through its full range each time.
(h) Disconnect the oil gun from the vent plug adaptor.
(i) Remove the vent plug adaptor from the flap actuator.
(j) Disconnect the waste hose from the drain plug adaptor.
(k) Remove the drain plug adapter from the flap actuator.
(l) Install the vent plug (1) in the flap actuator. Do not tighten it at this time.
(m) Install the drain plug (2) in the flap actuator. Do not tighten it at this time.
(3) Do steps (2)(a) thru (2)(m) and remove the unwanted semi-fluid from:

Flap actuator No. 2 6211CM (6261CM)
Flap actuator No. 3 6221CM (6271CM)
Flap actuator No. 4 6233CM (6283CM).

(4) Operate the flaps through their full range of travel five times again (Ref. AMM TASK 27-50-00-866-011) and (Ref. AMM TASK 27-50-00-866-012). After the last operation, make sure that the flaps are in the fully extended position.
(5) Do steps (2)(a) thru (2)(m) again for:

Flap actuator No. 1 6205CM (6255CM)
Flap actuator No. 2 6211CM (6261CM)
Flap actuator No. 3 6221CM (6271CM)
Flap actuator No. 4 6233CM (6283CM).

(6) TORQUE the vent plug (1) of each flap actuator as follows:
(a) Remove the vent plug (1) from the flap actuator.
(b) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the mating surfaces of the vent plug (1) and the offset gearbox.
(c) Install the vent plug (1) in the offset gearbox.
(d) TORQUE the vent plug (1) to between 6.6 and 5.4 m.N (58.41 and 47.79 lbf.in )

.
(7) T0RQUE the drain plug (2) of each flap actuator as follows:
(a) Remove the drain plug (2) from the flap actuator.
(b) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the mating surfaces of the drain plug (2) and the offset gearbox.
(c) Install the drain plug (2) in the offset gearbox.
(d) TORQUE the drain plug (2):

1 For flap actuator No. 1, TORQUE the drain plug (2) to between 6.6 and 5.4 m.N (58.41 and 47.79 lbf.in )

.

2 For flap actuator No. 2, TORQUE the drain plug (2) to between 6.6 and 5.4 m.N (58.41 and 47.79 lbf.in )

.

3 For flap actuator No. 3, TORQUE the drain plug (2) to between 4.4 and 3.6 m.N (38.94 and 31.86 lbf.in )

.

4 For flap actuator No. 4, TORQUE the drain plug (2) to between 4.4 and 3.6 m.N (38.94 and 31.86 lbf.in )

5. Close-up
Subtask 12-13-27-410-056-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) FOR [6205CM] (FLAP ACTUATOR 1), [6255CM] (FLAP ACTUATOR 1)
(a) Remove the 460005835 SLEEVE - GROUND LOCK from the MLG door actuating-cylinder.
(b) Remove the ACCESS PLATFORM 1M (3 FT)-ADJUSTABLE.
(c) Close applicable MLG door(s) 734 and/or 744 (Ref. AMM TASK 32-12-00-410-001).
(3) Install the applicable access panels:

(a) FOR [6211CM] (FLAP ACTUATOR 2)
Install access panel 573AB (Ref. AMM TASK 57-51-37-400-002).

(b) FOR [6261CM] (FLAP ACTUATOR 2)
Install access panel 673AB (Ref. AMM TASK 57-51-37-400-002).

(c) FOR [6221CM] (FLAP ACTUATOR 3)
Install access panel 575BB (Ref. AMM TASK 57-51-37-400-004).

(d) FOR [6271CM] (FLAP ACTUATOR 3)
Install access panel 675BB (Ref. AMM TASK 57-51-37-400-004).

(e) FOR [6233CM] (FLAP ACTUATOR 4)
Install access panel 575FB (Ref. AMM TASK 57-51-37-400-004).

(f) FOR [6283CM] (FLAP ACTUATOR 4)
Install access panel 675FB (Ref. AMM TASK 57-51-37-400-004).
(4) Remove the access platform(s).

Subtask 12-13-27-865-060-A ** ON A/C NOT FOR ALL

B. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B07
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
** ON A/C NOT FOR ALL
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 12-13-27-860-055-A ** ON A/C NOT FOR ALL

C. Put the Aircraft Back to its Original Configuration

WARNING: MAKE SURE THAT THE TRAVEL RANGES OF THE FLIGHT CONTROLS SURFACES ARE CLEAR. MOVEMENT OF FLIGHT CONTROLS CAN CAUSE INJURY TO PERSONS AND/OR DAMAGE TO EQUIPMENT.

(1) Remove the 98D27604000000 COLLAR-SAFETY, SPOILER or 98D27604004000 COLLAR SAFETY SPOILER from each spoiler servo-control.
(2) Retract the spoilers 1 thru 5 (Ref. AMM TASK 27-60-00-866-002).
(3) Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION from the flap/slat control lever (Ref. AMM TASK 27-00-00-080-002).
(4) Retract the flaps fully (Ref. AMM TASK 27-50-00-866-009).

Subtask 12-13-27-942-058-A ** ON A/C NOT FOR ALL

D. Removal of Equipment
(1) Remove the safety barriers.
(2) Remove the WARNING NOTICE(S).
(3) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

[Rev.10 from 2021] 2026.04.01 04:23:30 UTC