Installation of the Flap Track 3 Actuator

TASK 27-54-49-400-003-A
Installation of the Flap Track 3 Actuator

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.

FIN: 6221CM
FIN: 6271CM

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

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE
No specific	AR	CLAMPS
No specific	AR	ROD DIA 4 MM (0,157 IN)
No specific	AR	SAFETY BARRIER(S)
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 0.96 and 0.78 m.daN (84.96 and 69.03 lbf.in )
No specific	Torque wrench: range to between 3.0 and 2.8 m.daN (22.12 and 20.65 lbf.ft )
98D27504030001	2	LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT
98D27508002000	1	SET-CARRIAGE STOP,FLAP
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03FDB1)	Mineral Oil base Grease-Anti-Fretting Paste -
(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.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
FOR [6221CM] (FLAP ACTUATOR 3)
573BB, 575AB, 575BB, 575CB, 575DB
FOR [6271CM] (FLAP ACTUATOR 3)
673BB, 675AB, 675BB, 675CB, 675DB

D. Referenced Information

REFERENCE	DESIGNATION
TASK 20-28-00-869-002-A	Table of the Maximum Permitted Resistance-Values
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 24-41-00-861-002-A	Energize the Aircraft Electrical Circuits from the External Power
TASK 24-41-00-861-002-A-01	Energize the Aircraft Electrical Circuits from the APU
TASK 24-41-00-861-002-A-02	Energize the Aircraft Electrical Circuits from Engine 1(2)
TASK 27-50-00-000-003-A	Removal of the Lock-Torque Shaft - Flaps and Slats (98D27504030001)
TASK 27-50-00-400-003-A	Installation of the Lock-Torque Shaft - Flaps and Slats (98D27504030001)
TASK 27-50-00-860-801-A	Readout of the Flap Position Pickoff Unit (PPU) Data
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 27-51-44-820-001-A	Adjustment of the Interconnecting Strut
TASK 27-54-00-220-007-A	Check of the Flap Drive System
TASK 27-54-00-710-001-A	Operational Test of the Flap System
TASK 27-60-00-866-002-A	Extension-Retraction of the Spoilers for Maintenance
TASK 57-51-37-000-002-A	Removal of the Access Panels 571AB(671AB), 573AB(673AB), 573BB(673BB), 573CB(673CB), 573EB(673EB)
TASK 57-51-37-000-004-A	Removal of the Access Panels 575AB(675AB), 575BB(675BB), 575CB(675CB), 575DB(675DB), 575EB(675EB), 575FB(675FB), 575GB(675GB), 575HB(675HB)
TASK 57-51-37-400-002-A	Installation of the Access Panels 571AB(671AB), 573AB(673AB), 573BB(673BB), 573CB(673CB), 573EB(673EB)
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)
Flap Track 3 Actuator ** ON A/C NOT FOR ALL
Flap Track 3 Actuator ** ON A/C NOT FOR ALL
FOR [6221CM] (FLAP ACTUATOR 3)
TASK 27-54-45-400-007-A	Installation of the Torque Shafts
TASK 27-54-45-400-010-A	Installation of the Torque Shaft
FOR [6271CM] (FLAP ACTUATOR 3)
TASK 27-54-45-400-007-A	Installation of the Torque Shafts
TASK 27-54-45-400-010-A	Installation of the Torque Shaft

3. Job Set-up
Subtask 27-54-49-941-071-A

A. Safety Precautions

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 SAFETY BARRIER(S) are in position.
(2) Make sure that the WARNING NOTICE(S) is in position to tell persons not to operate the flight controls.

Subtask 27-54-49-860-057-A

B. Aircraft Maintenance Configuration
(1) Make sure that the flaps are in position 3 (Ref. AMM TASK 27-50-00-866-008).
(2) Make sure the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is on the flap/slat control lever in the cockpit.
(3) Make sure that the No 2 and the No 3 spoilers are extended (Ref. AMM TASK 27-60-00-866-002).
(4) Make sure that there is the 98D27604000000 COLLAR-SAFETY, SPOILER or the 98D27604004000 COLLAR SAFETY SPOILER on the piston rod of each servo-control.
(5) Make sure that the trailing edge of the flap is on a support.
(6) Make sure that the 98D27508002000 SET-CARRIAGE STOP,FLAP or the CLAMPS holds the carriage in position.
(7) Make sure that the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE is in position below the applicable access panel.
(8) Make sure that the applicable access panels are removed (Ref. AMM TASK 57-51-37-000-002) and (Ref. AMM TASK 57-51-37-000-004):
(a) FOR [6221CM] (FLAP ACTUATOR 3)

573BB 575AB 575BB 575CB 575DB.

(b) FOR [6271CM] (FLAP ACTUATOR 3)

673BB 675AB 675BB 675CB 675DB.

(9) Make sure that the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT are installed on the applicable torque shafts (Ref. AMM TASK 27-50-00-400-003).
(10) Make sure that the applicable torque shafts and the universal joint are removed.

Subtask 27-54-49-865-062-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
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
** ON A/C ALL
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21

4. Procedure
Subtask 27-54-49-560-051-A ** ON A/C NOT FOR ALL

A. Preparation for a Replacement Component
(1) Replacement actuator assemblies of flap track 3 are supplied in the Left Hand (LH) configuration. To change a replacement actuator of track 3 to a Right Hand (RH) configuration:

CAUTION: DO NOT DISENGAGE THESE ITEMS FROM THE OFFSET GEARBOX WHEN YOU CHANGE THE CONFIGURATION FROM LH TO RH :

THE TORQUE LIMITER
THE ROTARY ACTUATOR.

THESE ITEMS ARE NOT LRU'S AND ARE NOT INTERCHANGEABLE.

(a) Remove the nuts (12), the bolts (15) and the washers (11).
(b) Keep the mating surface of the torque limiter assembly (13) in contact with the offset gearbox (16). Turn the torque limiter assembly (13) until the arrow is aligned with the R mark on the offset gearbox (16).
(c) Install the bolts (15), the washers (11) and the nuts (12).
(d) TORQUE all the nuts (12) to between 0.96 and 0.78 m.daN (84.96 and 69.03 lbf.in )

.
(e) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to the bolts (15), the washers (11) and the nuts (12).
(2) Make sure the arrow on the rotary actuator (17) is between the lines on the offset gearbox (16).

NOTE: The arrow on the rotary actuator (17) and the marks on the offset gearbox (16) are the same for the LH and RH configurations.

(3) Make sure the flap track 3 actuator and the torque limiter are aligned.

Subtask 27-54-49-560-051-C ** ON A/C NOT FOR ALL

CAUTION: DO NOT DISENGAGE THESE ITEMS FROM THE OFFSET GEARBOX WHEN YOU CHANGE THE CONFIGURATION FROM LH TO RH :

THE TORQUE LIMITER
THE ROTARY ACTUATOR.

THESE ITEMS ARE NOT LRU'S AND ARE NOT INTERCHANGEABLE.

(a) Remove the nuts (11), the bolts (14) and the washers (10).
(b) Keep the mating surface of the torque limiter assembly (12) in contact with the offset gearbox (15). Turn the torque limiter assembly (12) until the arrow is aligned with the R mark on the offset gearbox (15).
(c) Install the bolts (14), the washers (10) and the nuts (11).
(d) TORQUE all the nuts (11) to between 0.96 and 0.78 m.daN (84.96 and 69.03 lbf.in )

.
(e) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to the bolts (14), the washers (10) and the nuts (11).
(2) Make sure the flap track 3 actuator and the torque limiter are aligned.

Subtask 27-54-49-420-083-A ** ON A/C NOT FOR ALL

B. General
(1) The flap actuator has an off-set gearbox and a rotary actuator. The rotary actuator is a vented unit filled with grease.
(2) It is normal for this grease to have some oil separation. The external surfaces of the rotary actuator may be moist with this separated oil as it is not a hermetically sealed unit. However, separated oil in the unit that touches the grease will be changed back during operation. The oil separation will decrease during in-service operation until the lubricant is in a condition that is stable. This is normal and will not cause damage to the unit.

Subtask 27-54-49-420-058-A

C. Preparation for Installation

CAUTION: DO NOT APPLY MORE THAN ONE TYPE OF LUBRICANT. GREASE AND ASSEMBLY PASTE DO NOT MIX.

(1) Clean the component interfaces and the adjacent areas with Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) .
(2) Clean these items with Textile-Lint free Cotton - (Material No.14SBA1) made moist with Non Aqueous Cleaner-General - - (Material No.08BAA9) :

the internal splines of the flap drive lever
the drive splines of the flap actuator
the internal splines of the torque limiter
the splined part of the universal joint (3).

(3) Do a visual inspection for the correct condition of the:

internal splines of the flap drive lever
drive splines of the flap actuator
internal splines of the torque limiter
splines of the universal joint (3).

(4) Do an inspection of the component interfaces and the adjacent area.
(5) Make sure that the parts retained from the removed component are clean and in the correct condition.

CAUTION: DO NOT APPLY MORE THAN ONE TYPE OF LUBRICANT. GREASE AND ASSEMBLY PASTE DO NOT MIX.

(6) Make sure that the surfaces of the items that follow are fully covered with thin layer of Mineral Oil base Grease-Anti-Fretting Paste - (Material No.03FDB1) :

the drive splines of the flap actuator
the internal splines of the flap drive lever
the internal splines of the torque limiter
the splines of the universal joint (3).

Subtask 27-54-49-420-067-A ** ON A/C NOT FOR ALL

D. Installation of the Flap Track 3 Actuator 6221CM(6271CM)

CAUTION: SUPPORT THE ACTUATOR, WHICH CAN WEIGH UP TO 10.5kg (23.2lbs). THIS WILL PREVENT DAMAGE TO THE RELATED STRUCTURE AND EQUIPMENT.

CAUTION: DO A CHECK OF THE FLAP DRIVE SYSTEM AND/OR THE INTERCONNECTING STRUT AFTER YOU INSTALL A FLAP ROTARY ACTUATOR. INCORRECT ALIGNMENT CAN CAUSE A FLAP TO BECOME LOCKED.

(1) Turn the actuator drive, as necessary, and engage the actuator drive in the flap drive lever.
(2) Do these steps if the bolt holes of the actuator assembly and the structure do not align:
(a) Put the universal joint (3) in the torque limiter.
(b) Turn the universal joint (3) until the bolt holes align.
(c) Remove the universal joint (3).
(3) Put a countersunk washer (6) on a bolt (7), with the countersink adjacent to the head of the bolt.
(4) Install the bolt (7), with the countersunk washer (6), one or two (as applicable) of the washers (10) and one of the nuts (9) in the applicable hole (Ref. AMM TASK 20-28-00-912-802):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
in the LH wing bonding position
(b) FOR [6271CM] (FLAP ACTUATOR 3)
in the RH wing bonding position.

NOTE: Do not tighten in this step. Do not apply sealant.

(5) Apply a layer of Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) or Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) to the shanks of the bolts (7).
(6) Put the countersunk washers (6) on the bolts (7), with the countersink adjacent to the heads of the bolts.
(7) Install the bolts (7) through the actuator assembly and the structure.
(8) Install the washers (10) and a nut (9) on each of the bolts (7).

NOTE: You must install the same number of washers (10) that you removed.

(9) TORQUE all the nuts (9) in a diagonally opposite sequence to between 3.0 and 2.8 m.daN (22.12 and 20.65 lbf.ft )

.
(10) Do an electrical bonding check between the structure and the applicable bolt (Ref. AMM TASK 20-28-00-869-002):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
in the LH wing bonding position
(b) FOR [6271CM] (FLAP ACTUATOR 3)
in the RH wing bonding position.
(11) Seal the bolt (7), the countersunk washers (6), the washer(s) (10) and the nut (9) in the applicable bonding position (Ref. AMM TASK 20-28-00-912-802):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
in the LH wing bonding position
(b) FOR [6271CM] (FLAP ACTUATOR 3)
in the RH wing bonding position.
(12) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to these remaining items:

the bolts (7) and the nuts (9)
the washers (6) and (10).

(13) Open the bottom of the two vent covers (8).
(14) Put the ROD DIA 4 MM (0,157 IN) through the vent into each hole of the bearing to make sure the holes are not blocked.
(15) Close the bottom vent cover (8).
(16) Install the universal joint (3) and the torque shafts (2) and (4):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
install 6222CM (Ref. AMM TASK 27-54-45-400-010) and 6220CM (Ref. AMM TASK 27-54-45-400-007)
(b) FOR [6271CM] (FLAP ACTUATOR 3)
install 6772CM (Ref. AMM TASK 27-54-45-400-010) and 6270CM (Ref. AMM TASK 27-54-45-400-007).

NOTE: If you install the related torque shafts, it is not necessary to extend the flaps fully. The flaps can stay in position 3.

Subtask 27-54-49-420-067-E ** ON A/C NOT FOR ALL

D. Installation of the Flap Track 3 Actuator 6221CM(6271CM)

CAUTION: SUPPORT THE ACTUATOR, WHICH CAN WEIGH UP TO 10.5kg (23.2lbs). THIS WILL PREVENT DAMAGE TO THE RELATED STRUCTURE AND EQUIPMENT.

CAUTION: DO A CHECK OF THE FLAP DRIVE SYSTEM AND/OR THE INTERCONNECTING STRUT AFTER YOU INSTALL A FLAP ROTARY ACTUATOR. INCORRECT ALIGNMENT CAN CAUSE A FLAP TO BECOME LOCKED.

(1) Turn the actuator drive, as necessary, and engage the actuator drive in the flap drive lever.
(2) Do these steps if the bolt holes of the actuator assembly and the structure do not align:
(a) Put the universal joint (3) in the torque limiter.
(b) Turn the universal joint (3) until the bolt holes align.
(c) Remove the universal joint (3).
(3) Put a countersunk washer (6) on a bolt (7), with the countersink adjacent to the head of the bolt.
(4) Install the bolt (7), with a countersunk washer (6), washer (9) and one of the nuts (8) in the applicable hole (Ref. AMM TASK 20-28-00-912-802):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
in the LH wing bonding position
(b) FOR [6271CM] (FLAP ACTUATOR 3)
in the RH wing bonding position.

NOTE: Do not tighten in this step. Do not apply sealant.

.
(10) Do an electrical bonding check between the structure and the applicable bolt (Ref. AMM TASK 20-28-00-869-002):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
in the LH wing bonding position
(b) FOR [6271CM] (FLAP ACTUATOR 3)
in the RH wing bonding position.
(11) Seal the bolt (7), the countersunk washer (6), the washer (9) and the nut (8) in the applicable bonding position (Ref. AMM TASK 20-28-00-912-802):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
in the LH wing bonding position
(b) FOR [6271CM] (FLAP ACTUATOR 3)
in the RH wing bonding position.
(12) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) to these remaining items:

the bolts (7) and the nuts (8)
the washers (6) and (9).

(13) Install the universal joint (3) and the torque shafts (2) and (4):
(a) FOR [6221CM] (FLAP ACTUATOR 3)
install 6222CM (Ref. AMM TASK 27-54-45-400-010) and 6220CM (Ref. AMM TASK 27-54-45-400-007)
(b) FOR [6271CM] (FLAP ACTUATOR 3)
install 6772CM (Ref. AMM TASK 27-54-45-400-010) and 6270CM (Ref. AMM TASK 27-54-45-400-007).

NOTE: If you install the related torque shafts, it is not necessary to extend the flaps fully. The flaps can stay in position 3.

Subtask 27-54-49-080-051-A

E. Removal of Support Equipment
(1) Remove the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT (Ref. AMM TASK 27-50-00-000-003).
(2) Remove the 98D27508002000 SET-CARRIAGE STOP,FLAP or the CLAMPS that holds the carriage in position.
(3) Remove the support from the flap trailing edge.

Subtask 27-54-49-740-076-A

F. Check of the Flap Drive System and/or Interconnecting Strut
(1) Do a check of the flap drive system (Ref. AMM TASK 27-54-00-220-007).
(2) Do the adjustment of the interconnecting strut (Ref. AMM TASK 27-51-44-820-001).

Subtask 27-54-49-740-065-A

G. Check of the PPU Data
(1) Energize the aircraft electrical circuits (Ref. AMM TASK 24-41-00-861-002).
(2) Do the readout and check of the PPU data (Ref. AMM TASK 27-50-00-860-801).

NOTE: The flaps can stay in position 1.

Subtask 27-54-49-820-064-A

H. Adjustment after Check of the PPU Datat
(1) If the PPU data are not in the specified limits, do these steps:
(a) Disconnect the APPU and adjust the APPU input shaft.
(b) Do step (1)(a) again until the PPU data are in the specified limits.

Subtask 27-54-49-860-060-A

I. Aircraft Maintenance Configuration
(1) Remove the access platform(s).
(2) Retract the No 2 and the No 3 spoilers (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 in the cockpit.
(4) Retract the flaps fully (Ref. AMM TASK 27-50-00-866-009).
(5) Make sure that the work area is clean and clear of tools and other items.

Subtask 27-54-49-865-063-A

J. 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/FLP/CTL AND/MONG/SYS2	8CV	Q21

Subtask 27-54-49-710-052-A

K. Test
(1) Do an operational test of the flaps (Ref. AMM TASK 27-54-00-710-001).

5. Close-up
Subtask 27-54-49-410-057-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the applicable access panels (Ref. AMM TASK 57-51-37-400-002) and (Ref. AMM TASK 57-51-37-400-004):
(a) FOR [6221CM] (FLAP ACTUATOR 3)

573BB 575AB 575BB 575CB 575DB.

(b) FOR [6271CM] (FLAP ACTUATOR 3)

673BB 675AB 675BB 675CB 675DB.

Subtask 27-54-49-942-055-A

B. 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] 2026.03.31 23:54:10 UTC