Installation of the Flexible Control Assembly

TASK 25-62-43-400-001-A
Installation of the Flexible Control Assembly

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

ZONE: 241
ZONE: 242
FIN: 5032WM ** ON A/C NOT FOR ALL
FIN: 5033WM ** ON A/C NOT FOR ALL

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
TLW101	1	TEST TOOL-RELEASE CABLE,ESCAPE SLIDE

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.06AEA1)	Polysulfide Sealant-Low Adhesion Brushable -
(Material No.14QFB1)	Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
241	CENTER PASSENGER COMPARTMENT
242	CENTER PASSENGER COMPARTMENT
FOR [5000WM]
FOR [5030WM] (FLEX.CONTROL ASSY)
151KW, 241CW, 241DW, 241LW, 241MW, 241QW, 241TW, 241UW, 241VW, 241WW
FOR [5001WM]
FOR [5031WM] (FLEX.CONTROL ASSY)
152KW, 241VW, 242CW, 242DW, 242LW, 242MW, 242QW, 242TW, 242UW, 242WW
FOR [7506MM] (RESERVOIR ASSY OWS L)
151KW
FOR [7507MM] (RESERVOIR ASSY OWS R)
152KW

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
3	COTTER PIN	AIPC 25-62-04-10-070
3	COTTER PIN	AIPC 25-62-84-30-070

E. Referenced Information

REFERENCE	DESIGNATION
TASK 20-11-11-911-001-A	Safetying with Lockwire
TASK 21-20-00-010-001-A	Removal of the Air-Conditioning Distribution Ducts
TASK 21-20-00-410-001-A	Installation of the Air-Conditioning Distribution Ducts
TASK 24-42-00-861-001-A	Energize the Ground Service Network from the External Power
TASK 24-42-00-862-001-A	De-energize the Ground Service Network Supplied from the External Power
TASK 25-21-41-000-001-A	Removal of the Passenger Seats
TASK 25-21-41-400-001-A	Installation of the Passenger Seats
TASK 25-23-43-000-001-A	Removal of the Upper Sidewall Panel
TASK 25-23-43-400-001-A	Installation of the Upper Sidewall Panel
TASK 25-23-44-000-001-A	Removal of the Lower Sidewall Panels (Dado Panels)
TASK 25-23-44-400-001-A	Installation of the Lower Sidewall Panels (Dado Panels)
TASK 25-23-47-000-803-A	Removal of the Door Lining from the Overwing Emergency Exit
TASK 25-23-47-400-002-A	Installation of the Upper Sidewall Panel Assy 241LW, (242LW), 241CW, (242CW) and 241FW, (242FW)
TASK 25-23-47-400-803-A	Installation of the Door Lining on the Overwing Emergency Exit
TASK 25-23-48-000-001-A	Removal of the Cove Light Panel
TASK 25-23-48-400-001-A	Installation of the Cove Light Panel
TASK 25-24-41-000-001-A	Removal of the Overhead Stowage Compartments (OHSC)
TASK 25-24-41-400-001-A	Installation of the Overhead Stowage Compartments (OHSC)
TASK 25-62-00-081-001-A	Special Precautions after Work on the Offwing Escape-Slide Systems
TASK 25-62-00-481-001-A	Special Precautions before Work on the Offwing Escape-Slide Systems
TASK 52-21-11-000-001-A	Removal of the Emergency Exit Hatch
TASK 52-21-11-400-001-A	Installation of the Emergency Exit Hatch
TASK 52-22-00-010-802-A	Opening of the Overwing Emergency-Exit Door from the Passenger Compartment
TASK 52-30-00-860-002-A	Close the FWD or Aft Cargo-Compartment Door with the Yellow Electric Pump
Flexible Control Assembly ** ON A/C NOT FOR ALL
Arming of the Slide Release Mechanism ** ON A/C NOT FOR ALL
Flexible Control Assembly ** ON A/C NOT FOR ALL
FOR [5001WM]
FOR [5031WM] (FLEX.CONTROL ASSY)
TASK 25-23-43-000-001-A	Removal of the Upper Sidewall Panel
TASK 25-23-44-000-001-A	Removal of the Lower Sidewall Panels (Dado Panels)
TASK 25-23-47-000-002-A	Removal of the Upper Sidewall Panel Assy 241LW, (242LW), 241CW, (242CW) and 241FW, (242FW)
TASK 25-23-48-000-001-A	Removal of the Cove Light Panel

3. Job Set-up
Subtask 25-62-43-860-051-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) In the aft cargo compartment:
(a) Make sure that the offwing escape-slide system is safe (Ref. AMM TASK 25-62-00-481-001).
(b) Make sure that this/these access panel(s) is/are removed:
1 FOR [5000WM] , [5030WM] (FLEX.CONTROL ASSY)
151KW
2 FOR [5001WM] , [5031WM] (FLEX.CONTROL ASSY)
152KW.
(2) In the passenger compartment:
(a) Make sure that the passenger seats in the area of the emergency exit(s) are removed as necessary (Ref. AMM TASK 25-21-41-000-001).
(b) Make sure that the emergency exit hatch(es) is/are removed (Ref. AMM TASK 52-21-11-000-001).
(c) Make sure that these cove light panels are removed:
1 FOR [5000WM] , [5030WM] (FLEX.CONTROL ASSY)
241DW 241MW 241QW 241TW 241WW
2 FOR [5001WM] , [5031WM] (FLEX.CONTROL ASSY)
242DW 242MW 242QW 242TW 242WW, (Ref. AMM TASK 25-23-48-000-001).
(d) Make sure that this/these upper sidewall panel(s) is/are removed:
1 FOR [5000WM] , [5030WM] (FLEX.CONTROL ASSY)
241VW
2 FOR [5001WM] , [5031WM] (FLEX.CONTROL ASSY)
241VW, (Ref. AMM TASK 25-23-43-000-001).
(e) Make sure that this/these lower sidewall panel(s) is/are removed:
1 FOR [5000WM] , [5030WM] (FLEX.CONTROL ASSY)
241UW
2 FOR [5001WM] , [5031WM] (FLEX.CONTROL ASSY)
242UW, (Ref. AMM TASK 25-23-44-000-001).
(f) Make sure that these emergency exit-frame linings are removed:
1 FOR [5000WM] , [5030WM] (FLEX.CONTROL ASSY)
241CW 241LW
2 FOR [5001WM] , [5031WM] (FLEX.CONTROL ASSY)
242CW 242LW, (Ref. AMM TASK 25-23-47-000-002).
(g) Make sure that the air conditioning duct(s) is/are removed as necessary (Ref. AMM TASK 21-20-00-010-001).

Subtask 25-62-43-860-051-D ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Make sure that the ground service network is energized
(Ref. AMM TASK 24-42-00-861-001).
(2) Make sure that the offwing escape-slide system is safetied (Ref. AMM TASK 25-62-00-481-001).
(3) Make sure that the passenger seats in the area of the emergency exit(s) are removed as necessary (Ref. AMM TASK 25-21-41-000-001).
(4) Make sure that the related overhead stowage compartments are removed (Ref. AMM TASK 25-24-41-000-001).
(5) Make sure that the related cove light panels are removed (Ref. AMM TASK 25-23-48-000-001).
(6) Make sure that the related upper sidewall panels are removed (Ref. AMM TASK 25-23-43-000-001).
(7) Make sure that the related lower sidewall panels are removed (Ref. AMM TASK 25-23-44-000-001).
(8) Make sure that the emergency exit-frame linings are removed (Ref. AMM TASK 25-23-47-000-803).
(9) Make sure that the air conditioning duct(s) is (are) removed as necessary (Ref. AMM TASK 21-20-00-010-001).

4. Procedure
Subtask 25-62-43-420-050-A ** ON A/C NOT FOR ALL

A. Install the Flexible Control Assembly 5000WM/5030WM (5001WM/5031WM)

Flexible Control Assembly ** ON A/C NOT FOR ALL

WARNING: MAKE SURE THAT THE LOCK PIN IS CORRECTLY INSTALLED IN THE REGULATOR VALVE ASSEMBLY OF THE INFLATION RESERVOIR. THIS SAFETIES ALL COMPONENTS OF THE INFLATION SYSTEM IN OPERATION AND PREVENTS ACCIDENTAL:

DISCHARGE OF THE INFLATION RESERVOIR
DEPLOYMENT OF THE ESCAPE SLIDE

WHICH CAN CAUSE INJURY AND/OR DAMAGE.

(1) Put the flexible control assembly (1) in position.
(2) Make sure that you can see the orientation mark on the flexible control assembly (1).
(3) Apply new sealant:

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

(a) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) to the flange attach bolts (9) and (12) and the nuts (11) and (13).
(4) Put the flange (14) in position and install and tighten the bolt (12) and the nut (13).
(5) Install and tighten the bolt (9), the washer (10) and the nut (11).
(6) Tighten the conduit adjust nuts (7) and (8).
(7) Connect the flexible control assembly (1) to the bellcrank (6) and install the washers (5) and the pin (4).
(8) Safety the pin (4) with a new AIPC 25-62-04-10-070 COTTER PIN (3) or AIPC 25-62-84-30-070 COTTER PIN (3) (3).
(9) Tighten the bracket attach nuts (15) and (16) with your fingers.
(10) Put the clamps (20) in position and install and tighten the washers (18), the screws (17) and the nuts (19) with your fingers.

NOTE: Make sure that the conduit of the flexible control assembly at FR47 has a minimum bend radius of 180.0 mm (7.0866 in.).

(11) At FR47, loosen the bracket attach nuts (15) and (16) and adjust the conduit housing to get these distances:
(a) Set the distance between the bottom end of the release cable and the bottom end of the conduit housing to 11.5 +1.7 mm or -1.7 mm (0.4528 +0.0669 in. or -0.0669 in.).
(b) Set the distance between the bottom end of the conduit housing and the top end of the attach bracket to 67.0 +2.0 mm or -2.0 mm (2.6378 +0.0787 in. or -0.0787 in.).
(12) Tighten the screws (17) with 2, 8-3, 7 Nm.
(13) Tighten the bracket attach nuts (15) and (16) and safety them with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.

Subtask 25-62-43-410-054-A ** ON A/C NOT FOR ALL

B. Preparation for Adjustment:

DISCHARGE OF THE INFLATION RESERVOIR
DEPLOYMENT OF THE ESCAPE SLIDE

WHICH CAN CAUSE INJURY AND/OR DAMAGE.

(1) In the passenger compartment:
(a) Install the emergency exit hatches and put them in the DISARMED/MANUAL position (Ref. AMM TASK 52-21-11-400-001).
(2) In the cargo compartment:
(a) Remove the cap and connect the TLW101 TEST TOOL-RELEASE CABLE,ESCAPE SLIDE adapter to the flexible control assembly.
(3) Set the test tool cursor to zero.
(4) Put the forward emergency exit hatch in the ARMED/AUTOMATIC position and remove the hatch (Ref. AMM TASK 52-21-11-000-001).

NOTE: During the removal of the hatch the flexible control assembly is operated when the latch pin moves the release lever.

(5) Make sure that the test tool cursor has moved to show a minimum indication of 50.0 mm (1.97 in.).
(6) If the test tool cursor shows less than the minimum indication, adjust the flexible control assembly as follows:

Subtask 25-62-43-820-050-A ** ON A/C NOT FOR ALL

C. Adjustment
(1) Make sure that the test tool cursor shows a minimum indication of 50.0 mm (1.9685 in.).
(2) If the test tool cursor shows less than the minimum indication, adjust the flexible control assembly as follows:
(a) Install the emergency exit hatch (Ref. AMM TASK 52-21-11-400-001).
(b) Adjust the conduit adjust nuts (7) and (8) on the flexible control assembly to adjust the conduit length.
(c) Do steps 4.B.(3) and (4) and 4.C.(1) again.
(3) Do steps 4.B (3) and (4) and 4.C.(1) and (2) with the rear emergency exit hatch.
(4) Safety the flange attach bolt (9) to the conduit adjust nut (7) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
(5) Safety the flange attach nut (11) to the conduit adjust nut (8) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
(6) Remove the test tool from the flexible control assembly (1).
(7) Connect the flexible control assembly (1) to the release cable assembly (21). Install the two collets and tighten the knurled sleeve nut (2).

NOTE: When you install the collets, the slots in the collets must point to you. This lets you do a visual check, that the inner cable stays connected while you tighten the knurled sleeve nut (2).

Subtask 25-62-43-710-050-A ** ON A/C NOT FOR ALL

D. Do this test:

DISCHARGE OF THE INFLATION RESERVOIR
DEPLOYMENT OF THE ESCAPE SLIDE

WHICH CAN CAUSE INJURY AND/OR DAMAGE.

(1) At the lower end of the release lever, try to lift the lever up with one finger. A strong resistance to lever movement shows that the joint between the flexible control assembly (1) and release cable assembly (21) is satisfactory.
(2) A low resistance to lever movement shows that the cable joint is not correct. Loosen the knurled sleeve nut (2), remove the two collets and make the cable joint again. Do step A again.
(3) Safety the knurled sleeve nut (2) with lockwirwe 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.

Subtask 25-62-43-420-050-D ** ON A/C NOT FOR ALL

E. Install the Flexible Control Assembly

DISCHARGE OF THE INFLATION RESERVOIR
DEPLOYMENT OF THE ESCAPE SLIDE

WHICH CAN CAUSE INJURY AND/OR DAMAGE.

(1) Put the flexible control assembly (1) in position.
(2) Make sure that you can see the orientation mark on the flexible control assembly (1).
(3) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) to the bolts (11).
(4) Put the flange (9) in position and install the washers (10) and the bolts (11).
(5) Tighten the bolts (11).
(6) Make sure that the flexible control assembly (1) is in the correct position on the flange (9).
(7) Tighten the conduit adjust nuts (12).
(8) Connect the flexible control assembly (1) and install the bolt (6), bushings (2) and (7), washers (3) and (8) and castellated nut (4).
(9) Safety the bolt (6) and the castellated nut (4) with a new cotter pin (5).
(10) Tighten the bracket attach nuts (15) and (16).
(11) Put the clamps (18) in position and install the washers (19), the screws (20) and the nuts (17).
(12) Tighten the nuts (17).
(13) Make sure that the conduit of the flexible control assembly at FR47 has a minimum bend radius of 180.0 mm (7.09 in.).
(14) Loosen the bracket attach nuts (15) and (16) and adjust the conduit housing to get these distances:
(a) Set the distance between the bottom end of the release cable and the bottom end of the conduit housing to 11.5 +1.7 mm or -1.7 mm (0.45 +0.07 in. or -0.07 in.).
(b) Set the distance between the bottom end of the conduit housing and the top end of the attach bracket to 58.8 +2.0 mm or -2.0 mm (2.31 +0.08 in. or -0.08 in.).
(15) Tighten the bracket attach nuts (15) and (16).

WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

(16) Safety the bracket attach nuts (15) and (16) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy - (Ref. AMM TASK 20-11-11-911-001).

Subtask 25-62-43-410-054-D ** ON A/C NOT FOR ALL

F. Preparation for Adjustment

DISCHARGE OF THE INFLATION RESERVOIR
DEPLOYMENT OF THE ESCAPE SLIDE

WHICH CAN CAUSE INJURY AND/OR DAMAGE.

(1) Make sure that the offwing escape-slide system is safetied (Ref. AMM TASK 25-62-00-481-001).
(2) Connect the TLW101 TEST TOOL-RELEASE CABLE,ESCAPE SLIDE adapter to the flexible control assembly.
(3) Set the test tool cursor to zero.
(4) Put the latch pins of the emergency exit doors to the ARMED position:

Arming of the Slide Release Mechanism ** ON A/C NOT FOR ALL

(a) If necessary, remove the handle cover (2) from the emergency exit door (1).
(b) Pull the shaft (6):

For the emergency exit door (1) 833 (844) to the right
For the emergency exit door (1) 834 (843) to the left.

(c) Make sure that the unlock lever (7) disengages from the disarm bracket (8).
(d) Push the unlock lever (7) to turn the shaft (6) counterclockwise and disengage it from the disarm bracket (4).
(e) Push the shaft (6) until the unlock lever engages:

For the emergency exit door (1) 833 (844) to the left
For the emergency exit door (1) 834 (843) to the right.

NOTE: The spring (5) holds the release lever (8) in the counterpart lever (3) of the fuselage.

(5) Open the emergency exit doors with the latch pin in the ARMED position (Ref. AMM TASK 52-22-00-010-802).

NOTE: When the latch pin of the related emergency exit door is in the ARMED position and the emergency exit door is opened, then the flexible control assembly is operated.

Subtask 25-62-43-820-050-C ** ON A/C NOT FOR ALL

G. Adjustment

Flexible Control Assembly ** ON A/C NOT FOR ALL

(1) Make sure that the test tool cursor shows a minimum indication of 50.0 mm (1.97 in.).
(2) If the test tool cursor shows less than the minimum indication, adjust the flexible control assembly as follows:
(a) Adjust the conduit adjust nuts (12) on the flexible control assembly (1) to adjust the conduit length.
(b) Do steps 4.B.(3) thru (5) and 4.C.(1) again.
(3) Do steps 4.B (3) thru (5) and 4.C.(1) and (2) with the rear emergency exit hatch.

(4) Safety the conduit adjust nuts (12) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy - (Ref. AMM TASK 20-11-11-911-001).
(5) Remove the test tool from the flexible control assembly (1).
(6) Connect the flexible control assembly (1) to the release cable assembly (14). Install the two collets and tighten the knurled sleeve nut (13).

NOTE: When you install the collets, the slots in the collets must point to you. This lets you do a visual check, that the inner cable stays connected while you tighten the knurled sleeve nut (13).

Subtask 25-62-43-710-050-C ** ON A/C NOT FOR ALL

H. Do this test:

DISCHARGE OF THE INFLATION RESERVOIR
DEPLOYMENT OF THE ESCAPE SLIDE

WHICH CAN CAUSE INJURY AND/OR DAMAGE.

(1) At the lower end of the release lever, try to lift the lever up with one finger. A strong resistance to lever movement shows that the joint between the flexible control assembly (1) and release cable assembly (14) is satisfactory.
(2) A low resistance to lever movement shows that the cable joint is not correct. Loosen the knurled sleeve nut (13), remove the two collets and make the cable joint again. Do step (1) again.

(3) Safety the knurled sleeve nut (13) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy - (Ref. AMM TASK 20-11-11-911-001).

5. Close-up
Subtask 25-62-43-410-050-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) Install the air conditioning duct (Ref. AMM TASK 21-20-00-410-001).
(3) Install the emergency exit-frame linings (Ref. AMM TASK 25-23-47-400-002).
(4) Install the lower sidewall panel (Ref. AMM TASK 25-23-44-400-001).
(5) Install the upper sidewall panel (Ref. AMM TASK 25-23-43-400-001).
(6) Install the cove light panels (Ref. AMM TASK 25-23-48-400-001).
(7) Install the emergency exit hatches (Ref. AMM TASK 52-21-11-400-001).
(8) Install the passenger seats (Ref. AMM TASK 25-21-41-400-001).

CAUTION: MAKE SURE THAT THE LOCK PIN IS REMOVED FROM THE REGULATOR VALVE ASSEMBLY OF THE INFLATION RESERVOIR. IF IT IS NOT REMOVED, IT CAN PREVENT THE INFLATION OF THE ESCAPE SLIDE/RAFT.

(9) Remove the lockpin assembly from the valve/regulator assembly of the inflation reservoir (Ref. AMM TASK 25-62-00-081-001).
(10) FOR [7506MM] (RESERVOIR ASSY OWS L)
(a) Install the access panel 151KW
(11) FOR [7507MM] (RESERVOIR ASSY OWS R)
(a) Install the access panel 152KW.
(12) Set the AFT CARGO COMPT light switch 8LU to the OFF position.
(13) Remove the access platform(s).
(14) Close the AFT cargo-compartment door (Ref. AMM TASK 52-30-00-860-002).

Subtask 25-62-43-410-050-D ** 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) Install the air conditioning duct(s) (Ref. AMM TASK 21-20-00-410-001).
(3) Install the emergency exit-frame linings (Ref. AMM TASK 25-23-47-400-803).
(4) Install the lower sidewall panels (Ref. AMM TASK 25-23-44-400-001).
(5) Install the upper sidewall panels (Ref. AMM TASK 25-23-43-400-001).
(6) Install the cove light panels (Ref. AMM TASK 25-23-48-400-001).
(7) Install the overhead stowage compartments (Ref. AMM TASK 25-24-41-400-001).
(8) Install the passenger seats (Ref. AMM TASK 25-21-41-400-001).
(9) Do the special precautions after work on the offwing escape-slide system (Ref. AMM TASK 25-62-00-081-001).

Subtask 25-62-43-862-052-A ** ON A/C NOT FOR ALL

B. De-energize the ground service network
(Ref. AMM TASK 24-42-00-862-001).

[Rev.10 from 2021] 2026.03.31 23:40:22 UTC