Installation of the Nos 2, 3 and 4 Flap Carriages

TASK 27-54-46-400-001-A
Installation of the Nos 2, 3 and 4 Flap Carriages

WARNING: MAKE SURE THAT THE FLIGHT CONTROL SAFETY-LOCKS AND THE WARNING NOTICES ARE IN POSITION.

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.

CAUTION: THIS PART IS A REMOVABLE STRUCTURAL COMPONENT (RSC), WHICH CAN BE MOVED BETWEEN AIRCRAFT. THUS IT CAN HAVE DIFFERENT OPERATION CONDITIONS AND A DIFFERENT LIFE RECORD (FLIGHT HOURS/FLIGHT CYCLES/CALENDAR) FROM THE AIRCRAFT IT IS INSTALLED ON OR REMOVED FROM. THE OPERATOR IS RESPONSIBLE FOR THE SPECIFIC TRACKING AND CONTINUED AIRWORTHINESS OF REMOVABLE STRUCTURAL COMPONENTS. INCORRECT MAINTENANCE OF THESE COMPONENTS CAN CAUSE A RISK FOR THE FLIGHT SAFETY.

ZONE: 530
ZONE: 630

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

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE
No specific	AR	SAFETY BARRIER(S)
No specific	AR	SPATULA - PLASTIC
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 15.8 and 13.5 m.N (139.82 and 119.47 lbf.in )
No specific	Torque wrench: range to between 30 and 26 m.N (22.12 and 19.17 lbf.ft )
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03GBC1)	Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. -
(Material No.03GBD1)	Synthetic Oil base Grease-General Purpose Lithium Thickened -
(Material No.03HBD9)	Synthetic Ester base Grease-General Purpose Low Temp -
(Material No.06AEA1)	Polysulfide Sealant-Low Adhesion Brushable -
(Material No.06AEB2)	Polysulfide Sealant-Low Adhesion Fillet Structure
(Material No.08BAA9)	Non Aqueous Cleaner-General - -
(Material No.12ACC1)	Corrosion Preventive Compound-Heavy Duty Soft Film -
(Material No.14QFB1)	Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
530	L WG FLAP TAB, FLAP TRACK FAIR & WG TIP
630	RIGHT WING FLAP TRACK FAIR AND WING TIP

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 27-54-00-710-001-A	Operational Test of the Flap System
TASK 27-54-61-400-001-A	Installation of the Inboard Flap
TASK 27-54-61-400-003-A	Installation of the Inboard Double-Slotted Flap
TASK 27-54-62-400-001-A	Installation of the Outboard Flap
TASK 27-54-62-400-002-A	Installation of the Outboard Double-Slotted Flap
Nos 2, 3 and 4 Flap Carriages ** ON A/C NOT FOR ALL
Nos 2, 3 and 4 Flap Carriages ** ON A/C NOT FOR ALL

3. Job Set-up
Subtask 27-54-46-941-062-A

A. Safety Precautions
(1) On panel 114VU, make sure that the WARNING NOTICE(S) is(are) in position to tell persons not to operate the flap/slat controls.
(2) Make sure that the SAFETY BARRIER(S) are in position.

Subtask 27-54-46-860-055-A

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) Make sure that the flaps are fully extended (Ref. AMM TASK 27-50-00-866-008).
(2) On panel 114VU, make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the flap/slat control lever.
(3) Make sure that the safety collar is removed from circuit breakers 10CV and 12CV.
(4) Make sure that the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE is in position adjacent to the applicable flap carriage.

Subtask 27-54-46-865-051-A

C. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B07
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B06
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B01
** ON A/C ALL
121VU	FLIGHT CONTROLS/WTB/FLP/SYS2	12CV	P20
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21
121VU	FLIGHT CONTROLS/SLT/CTL/SYS2	7CV	R21
122VU	FLIGHT CONTROLS/WTB/FLP/SYS1	10CV	S07

Subtask 27-54-46-560-050-B

D. Preparation of a Replacement Component

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.

(1) Remove and discard the lockwire from the lockbolts (17).
(2) Remove the lockbolts (17) from the lockplates (21).
(3) Remove the lockplates (21) from the adjuster screws (22).
(4) Make sure the nuts (20) are hand tight only.
(5) Loosen the adjuster screws (22). The bearing blocks (19) must be free to turn around the hinge bolts (18).

4. Procedure
Subtask 27-54-46-420-055-B

A. Preparation for Installation
(1) Use a SPATULA - PLASTIC to remove all the unwanted sealant from:

The end stop (10)
The flap beam end-stop (10) interface.

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

The top and bottom faces of the flap track (4)
The flap carriage (26)
The carriage roller greasers (6)
The flap beam end-stop (10) interface.

(3) Do an inspection for the correct condition of:

The top and bottom faces of the flap track (4)
The flap carriage (26)
The carriage roller greasers (6)
The flap beam end-stop (10) interface.

(4) Make sure that the parts retained from the removed component are clean and in the correct condition.

Subtask 27-54-46-420-053-B ** ON A/C NOT FOR ALL

B. Installation of the No. 2, 3 and 4 Flap Carriages
(1) Install the flap carriage (26) on the flap track beam (24). Make sure that the mal-assembly bracket (40) is outboard and the bonding contacts (27) point forward.
(2) Hold the flap carriage (26) at the forward end of the flap track beam (24).
(3) Apply a layer of Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) or Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) to the mating surfaces of the end stop (10) and the smooth part of the bolts (7), (9) and (13).
(4) Install the end stop (10) on the flap track beam (24).
(5) Install the bolts (7), washers (12) and nuts (11).
(6) TORQUE the nuts (11) to between 15.8 and 13.5 m.N (139.82 and 119.47 lbf.in )

.
(7) Install the bolts (9) and (13), washers (8) and (14) and nuts (15) and (16).
(8) TORQUE the nuts (15) and (16) to between 30 and 26 m.N (22.12 and 19.17 lbf.ft )

.
(9) Use Textile-Lint free Cotton - (Material No.14SBA1) and Non Aqueous Cleaner-General - - (Material No.08BAA9) to remove all the unwanted Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) from the:

End stop (10)
Flap track beam (24).

Subtask 27-54-46-420-053-D ** ON A/C NOT FOR ALL

B. Installation of the No. 2, 3 and 4 Flap Carriages
(1) Install the flap carriage (26) on the flap track beam (24). Make sure that the bonding contacts (27) point forward.
(2) Hold the flap carriage (26) at the forward end of the flap track beam (24).
(3) Apply a layer of Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) or Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) to the mating surfaces of the end stop (10) and the smooth part of the bolts (7), (9) and (13).
(4) Install the end stop (10) on the flap track beam (24).
(5) Install the bolts (7), washers (12) and nuts (11).
(6) TORQUE the nut (11) to between 15.8 and 13.5 m.N (139.82 and 119.47 lbf.in )

.
(7) Install the bolts (9) and (13), washers (8) and (14) and nuts (15) and (16).
(8) TORQUE the nuts (15) and (16) to between 30 and 26 m.N (22.12 and 19.17 lbf.ft )

.
(9) Use Textile-Lint free Cotton - (Material No.14SBA1) and Non Aqueous Cleaner-General - - (Material No.08BAA9) to remove all unwanted Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) from the:

End stop (10)
Flap track beam (24).

Subtask 27-54-46-820-050-B

C. Adjustment of the Flap Carriage Rollers

(1) Make sure the clearance (dimension 'Y') between the forward bottom roller (5) and the flap track (4) is more than 0.05 mm (0.002 in.).
(2) Measure the clearance (dimension 'X') between the aft bottom roller (3) and the flap track (4). Dimension 'X' must be 0.38 mm (0.015 in.).
(3) Move the flap carriage (26) along the flap track (4). The full travel of the flap carriage (26) must be smooth.
(4) Tighten the aft adjuster screw (22) sufficiently to decrease the dimension 'X' to 0.05 mm (0.002 in.). Do step 3 again.
(5) Tighten the forward adjuster screw (22) sufficiently to decrease the dimension 'Y' to 0.05 mm (0.002 in.). Do step 3 again.
(6) If the flap carriage (26) does not move smoothly along the flap track (4), then loosen the applicable adjuster screw (22) sufficiently until it does.
(7) Install the lockplate (21) on the forward adjuster screw (22). One of the holes in the lockplate (21) must align with the hole in the flap carriage (26). If necessary, tighten the forward adjuster screw (22) to align the holes. Do step 6 again.
(8) Install the forward lockbolt (17) through the lockplate (21).
(9) Install the lockplate (21) on the aft adjuster screw (22). One of the holes in the lockplate (21) must align with the hole in the flap carriage (26). If necessary, tighten the aft adjuster screw (22) to align the holes. Do step 6 again.
(10) Install the aft lockbolt (17) through the lockplate (21).
(11) Safety the forward and aft lockbolts (17) independently with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.

Subtask 27-54-46-420-052-C ** ON A/C NOT FOR ALL

D. Continue the Installation of the Nos 2, 3 and 4 Flap Carriages

(1) Tighten the nuts (20) and safety them independently with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
(2) If you install a new flap carriage (26), make sure that the nuts (25) are hand tight only.

NOTE: The nuts (25) are torque tightened and safetied when the flap is installed.

(3) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to:

The bolts (7), washers (12) and nuts (11)
The bolts (9) and (13), washers (8) and (14), and nuts (15) and (16)
The forward lockbolt (17) and aft adjuster screw (19)
The hinge bolts (18) and nuts (20).

(4) Lubricate the flap carriage (26) with Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) through the carriage roller greasers (6).

Subtask 27-54-46-420-052-D ** ON A/C NOT FOR ALL

D. Continue the Installation of the Nos 2, 3 and 4 Flap Carriages

NOTE: You must apply the torque to nuts (25) and safety them when the flap is installed.

(3) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to:

The bolts (7), washers (12) and nuts (11)
The bolts (9) and (13), washers (8) and (14), and nuts (15) and (16)
The forward lockbolt (17) and aft adjuster screw (19)
The hinge bolts (18) and nuts (20).

(4) Lubricate the flap carriage (26) with Synthetic Oil base Grease-General Purpose Lithium Thickened - (Material No.03GBD1) or Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. - (Material No.03GBC1) through the carriage roller greasers (6).

Subtask 27-54-46-410-050-A ** ON A/C NOT FOR ALL

E. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the applicable flap:

For the No 2 carriage, the inboard flap (Ref. AMM TASK 27-54-61-400-001)
For the Nos 3 and 4 carriages, the outboard flap (Ref. AMM TASK 27-54-62-400-001).

(3) Make sure that the work area is clean and clear of tools and other items.
(4) Remove the access platform(s).

Subtask 27-54-46-410-050-B ** ON A/C NOT FOR ALL

E. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the applicable flap:

For the No 2 carriage, the inboard flap (Ref. AMM TASK 27-54-61-400-003)
For the Nos 3 and 4 carriages, the outboard flap (Ref. AMM TASK 27-54-62-400-002).

(3) Make sure that the work area is clean and clear of tools and other items.
(4) Remove the access platform(s).

Subtask 27-54-46-865-052-A

F. 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 ALL
121VU	FLIGHT CONTROLS/WTB/FLP/SYS2	12CV	P20
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21
122VU	FLIGHT CONTROLS/WTB/FLP/SYS1	10CV	S07

Subtask 27-54-46-710-050-A

G. Operational Test

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) Install the safety collar on circuit breakers 10CV and 12CV.
(2) On panel 114VU, remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION from the flap/slat control lever.
(3) Fully retract the flaps (Ref. AMM TASK 27-50-00-866-009).
(4) Do an operational test of the flaps (Ref. AMM TASK 27-54-00-710-001).

5. Close-up
Subtask 27-54-46-942-051-A

A. 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 07:00:38 UTC