Quantity Check of the Semi-Fluid remaining in an Offset Gearbox of the Flap Rotary Actuator Unit (After Leakage)

TASK 27-54-00-612-802-A
Quantity Check of the Semi-Fluid remaining in an Offset Gearbox of the Flap Rotary Actuator Unit (After Leakage)

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

1. Reason for the Job
Do a check of the quantity of semi-fluid remaining in an Offset Gearbox of the Flap Rotary Actuator Unit (after leakage). Do this task only on actuators that show a leakage.
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 0.44 and 0.36 m.daN (38.94 and 31.86 lbf.in )
No specific	Torque wrench: range to between 0.66 and 0.54 m.daN (58.41 and 47.79 lbf.in )
A685064	1	MEASURING-EQUIPMENT, SEMIFUID
FOR [6205CM] (FLAP ACTUATOR 1)
FOR [6255CM] (FLAP ACTUATOR 1)
No specific	1	ACCESS PLATFORM 3M (10 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
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 27-50-00-866-008-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 27-54-49-000-001-A	Removal of the Flap Track 1 Actuator
TASK 27-54-49-000-002-A	Removal of the Flap Track 2 Actuator
TASK 27-54-49-000-003-A	Removal of the Flap Track 3 Actuator
TASK 27-54-49-000-004-A	Removal of the Flap Track 4 Actuator
TASK 27-54-49-400-001-A	Installation of the Flap Track 1 Actuator
TASK 27-54-49-400-002-A	Installation of the Flap Track 2 Actuator
TASK 27-54-49-400-003-A	Installation of the Flap Track 3 Actuator
TASK 27-54-49-400-004-A	Installation of the Flap Track 4 Actuator
TASK 27-60-00-866-002-A	Extension-Retraction of the Spoilers for Maintenance
Flap Actuator - Semi-fluid Measuring Equipment
Flap Actuator Offset Gearbox - Example
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 27-54-00-941-072-A ** ON A/C NOT FOR ALL

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

Subtask 27-54-00-860-089-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) Extend the spoilers 1 thru 5 (Ref. AMM TASK 27-60-00-866-002).

Subtask 27-54-00-865-093-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
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 27-54-00-010-072-A ** ON A/C NOT FOR ALL

D. Get Access
(1) FOR [6205CM] (FLAP ACTUATOR 1), [6255CM] (FLAP ACTUATOR 1)
(a) Open the applicable Main Landing Gear (MLG) door 734 744 (Ref. AMM TASK 32-12-00-010-001).
(b) Put the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE in position in the applicable MLG bay.
(2) FOR [6211CM] (FLAP ACTUATOR 2), [6261CM] (FLAP ACTUATOR 2)
(a) Put the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE below the applicable zone 573 (673).
(b) FOR [6211CM] (FLAP ACTUATOR 2)

Remove the access panel 573AB (Ref. AMM TASK 57-51-37-000-002).

Remove the 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 3M (10 FT)- ADJUSTABLE below the applicable zone 575 (675).
(b) FOR [6221CM] (FLAP ACTUATOR 3)

Remove the access panel 575BB (Ref. AMM TASK 57-51-37-000-004).

Remove the access panel 675BB (Ref. AMM TASK 57-51-37-000-004).

(d) FOR [6233CM] (FLAP ACTUATOR 4)

Remove the access panel 575FB (Ref. AMM TASK 57-51-37-000-004).

(e) FOR [6283CM] (FLAP ACTUATOR 4)

Remove the 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.

Subtask 27-54-00-612-051-A ** ON A/C NOT FOR ALL

A. Filling procedure for the Offset Gearboxes of:

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

(1) Fill the 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 clean Textile-Lint free Cotton - (Material No.14SBA1) and the Non Aqueous Cleaner-General - - (Material No.08BAA9) to clean:

The area around the vent plug (1)
The area around the drain plug (2).

(b) Remove the vent plug (1) from the flap actuator unit.
(c) Remove the drain plug (2) from the flap actuator unit.

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

(d) Use the semi-fluid A685064 MEASURING-EQUIPMENT, SEMIFUID to fill the flap actuator offset gearbox as follows:
1 Connect one end of the hose to the semi-fluid pump. Connect the other end of the hose to the tee piece.
2 Fill the semi-fluid pump with the Synthetic Oil base Grease-Gearboxes or Rotary actuator Lithium Thickened Semi-fluid - (Material No.03GDB1) . Bleed the semi-fluid pump before you operate it.
3 When you have bled the semi-fluid pump, record the volume of the remaining semi-fluid in the pump.
4 Install the tee piece and the adaptor into the hole of the drain plug (2) of the flap actuator unit. Tighten the adaptor with your hand.
(e) Operate the semi-fluid pump as follows:
1 Loosen the lock screw of one plunger on the semi-fluid pump.
2 Operate the plunger to fill the flap actuator offset gearbox with the Synthetic Oil base Grease-Gearboxes or Rotary actuator Lithium Thickened Semi-fluid - (Material No.03GDB1) .
3 If one plunger chamber is empty, tighten the plunger lock screw and continue with the remaining plunger. Do this until the semi-fluid comes out of the vent plug hole of the flap actuator unit.
4 Calculate and record the volume of semi-fluid to fill the flap actuator offset gearbox.
(f) Remove the semi-fluid pump, the hose, the tee piece and the adaptor from the flap actuator unit.
(g) Install (but do not torque) the vent plug (1) in the flap actuator unit.
(h) Install (but do not torque) the drain plug (2) in the flap actuator unit.
(2) Do the steps (1)(a) thru (1)(h) again for the:

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

(3) Torque tighten the vent plug (1) of each flap actuator unit as follows:
(a) Remove the vent plug (1) from the flap actuator.
(b) Apply the Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) to the mating surfaces of the vent plug (1) and the flap actuator unit.
(c) Install the vent plug (1) in the flap actuator and TORQUE the vent plug to between 0.66 and 0.54 m.daN (58.41 and 47.79 lbf.in )

.
(4) Torque the drain plug (2) of each flap actuator unit as follows:
(a) Remove the drain plug (2) from the flap actuator unit.
(b) Apply the Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) to the mating surfaces of the drain plug (2) and the flap actuator unit.
(c) Install the drain plug (2) in the flap actuator unit and TORQUE the drain plug as follows:

Flap actuator unit No.1 and No.2 to between 0.66 and 0.54 m.daN (58.41 and 47.79 lbf.in )
Flap actuator unit No.3 and No.4 to between 0.44 and 0.36 m.daN (38.94 and 31.86 lbf.in ) .

(5) Refer to Para 4.C for the permitted volumes of semi-fluid to fill the flap actuator(s).

Subtask 27-54-00-680-051-A ** ON A/C NOT FOR ALL

B. Removal Procedure for Unwanted Semi-fluid from the Offset Gearboxes of:

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

(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 operation, make sure that the flaps are in the fully extended position.
(2) Use the A685064 MEASURING-EQUIPMENT, SEMIFUID to remove the unwanted semi-fluid from the flap actuator No.1 6205CM (6255CM), as follows:
(a) Remove the vent plug (1) from the flap actuator unit.
(b) Remove the drain plug (2) from the flap actuator unit.

NOTE: The drain plug (2) is at the bottom location on the flap actuator unit.

(c) Install the tee piece and the adaptor into the hole of the vent plug (1) of the flap actuator unit. Tighten the adaptor with your hand.
(d) Connect one end of the hose to the air pump. Connect the other end of the hose to the tee piece.
(e) Install the remaining tee piece, adaptor and hose into the hole of the drain plug (2) of the flap actuator. Tighten the adaptor with your hand.
(f) Operate the air pump 15 times to put air into the flap actuator. This will push out the unwanted semi-fluid through the drain plug hole. Make sure that you operate the air pump handle through its full range each time.
(g) Remove the air pump, hose, tee piece and the adaptor from the hole of vent plug (1).
(h) Remove the hose, tee piece and the adaptor from the hole of the drain plug (2).
(i) Install (but do not torque) the vent plug (1) in the flap actuator unit.
(j) Install (but do not torque) the drain plug (2) in the flap actuator unit .
(3) Do the steps (2)(a) thru (2)(j) again and remove the unwanted semi-fluid from the:

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

(4) Torque the vent plug (1) of each flap actuator unit as follows:
(a) Remove the vent plug (1) from the flap actuator unit.
(b) Apply the jointing compound Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) to the mating surfaces of the vent plug (1) and the flap actuator unit.
(c) Install the vent plug (1) in the flap actuator unit and TORQUE the vent plug to between 0.66 and 0.54 m.daN (58.41 and 47.79 lbf.in )

.
(5) Torque the drain plug (2) of each flap actuator unit as follows:
(a) Remove the drain plug (2) from the flap actuator unit.
(b) Apply the jointing compound Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) to the mating surfaces of the drain plug (2) and the flap actuator.
(c) Install the drain plug (2) in the flap actuator unit and TORQUE the drain plug as follows:

Flap actuator unit No.1 and No.2 to between 0.66 and 0.54 m.daN (58.41 and 47.79 lbf.in )
Flap actuator unit No.3 and No.4 to between 0.44 and 0.36 m.daN (38.94 and 31.86 lbf.in ) .

Subtask 27-54-00-200-054-A ** ON A/C NOT FOR ALL

C. Permitted Volumes of Semi-fluid
(1) Compare the quantity of semi-fluid added to the flap actuator offset gearboxes and recorded in step 4.A.(1)(e)4_, with the maximum values shown on the table that follows:

Actuator P/N	Maximum Volume of Semi-fluid permitted (CM3)
791A0000-05/-06	103
792A0000-06/-07	83
793A0000-06/-08	72
794A0000-05/-06	128
1070B0000-03/-04	256
1071B0000-03/-04	256
1072A0000-03/-04	117
1073A0000-03/-04	129
1074A0000-03/-04	141

(a) If the volume of semi-fluid, added to flap the actuator offset gearbox, is less than the values in the table:

The flap actuator is serviceable.

(b) If the volume of semi-fluid, added to the flap actuator offset gearbox, is more than the values in the table, replace the flap actuator before 1200FH:

for Flap Track 1 Actuator 6205CM(6255CM)
(Ref. AMM TASK 27-54-49-000-001) and (Ref. AMM TASK 27-54-49-400-001)
for Flap Track 2 Actuator 6211CM(6261CM)
(Ref. AMM TASK 27-54-49-000-002) and (Ref. AMM TASK 27-54-49-400-002)
for Flap Track 3 Actuator 6221CM(6271CM)
(Ref. AMM TASK 27-54-49-000-003) and (Ref. AMM TASK 27-54-49-400-003)
for Flap Track 4 Actuator 6233CM(6283CM)
(Ref. AMM TASK 27-54-49-000-004) and (Ref. AMM TASK 27-54-49-400-004).

5. Close-up
Subtask 27-54-00-410-065-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) Close the applicable MLG door 734 744 (Ref. AMM TASK 32-12-00-410-001).
(3) Install the applicable access panel:
(a) FOR [6211CM] (FLAP ACTUATOR 2)
Install the access panel 573AB (Ref. AMM TASK 57-51-37-400-002)
(b) FOR [6261CM] (FLAP ACTUATOR 2)
Install the access panel 673AB (Ref. AMM TASK 57-51-37-400-002)
(c) FOR [6221CM] (FLAP ACTUATOR 3)
Install the access panel 575BB (Ref. AMM TASK 57-51-37-400-004)
(d) FOR [6271CM] (FLAP ACTUATOR 3)
Install the access panel 675BB (Ref. AMM TASK 57-51-37-400-004)

(e) FOR [6233CM] (FLAP ACTUATOR 4)
Install the access panel 575FB (Ref. AMM TASK 57-51-37-400-004)
(f) FOR [6283CM] (FLAP ACTUATOR 4)
Install the access panel 675FB (Ref. AMM TASK 57-51-37-400-004).
(4) Remove the access platform(s).

Subtask 27-54-00-865-094-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
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 27-54-00-860-090-A ** ON A/C NOT FOR ALL

C. Put the aircraft back to its initial configuration.
(1) Retract the spoilers 1 thru 5 (Ref. AMM TASK 27-60-00-866-002).
(2) Retract the flaps fully (Ref. AMM TASK 27-50-00-866-009).

Subtask 27-54-00-942-077-A ** ON A/C NOT FOR ALL

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

[Rev.10 from 2021] 2026.03.31 23:53:11 UTC