Installation of the Power Control Unit of the Flap System

TASK 27-54-51-400-001-A
Installation of the Power Control Unit of the Flap System

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.

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.

FIN: 6201CM

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)
No specific	1	ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE
No specific	1	CONTAINER 5 L (1.32 USGAL)
No specific	AR	TIE WRAP
No specific	1	WARNING NOTICE(S)
No specific	Torque wrench: range to between 1.24 and 1.02 m.daN (109.73 and 90.27 lbf.in )
No specific	Torque wrench: range to between 1.7 and 1.5 m.daN (12.54 and 11.06 lbf.ft )
No specific	Torque wrench: range to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )
98D27504030001	3	LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.02ABA1)	Phosphate Ester Hydraulic Fluid-General Power - -
(Material No.03FDB1)	Mineral Oil base Grease-Anti-Fretting Paste -
(Material No.04QAB2)	Coating_- Flexible Structure
(Material No.06AAA1)	Polysulfide Sealant_General Purpose Brushable -
(Material No.08BBB1)	Non Aqueous Cleaner-- Petroleum Based -
(Material No.12AGC2)	Corrosion Preventive Compound-- Soft Film System
No specific	lockwire, corrosion-resistant steel, dia. 0.8 mm (0.032 in.)

C. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
8	COTTER PINS	AIPC 27-54-03-04-050
8	COTTER PINS	AIPC 27-54-83-03-110

D. Referenced Information

REFERENCE	DESIGNATION
TASK 12-12-29-611-001-A	Fill the Hydraulic Fluid Reservoir with a Hand Pump
TASK 12-12-29-611-002-A	Fill the Hydraulic Fluid Reservoir with a Hydraulic Service Cart
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 27-00-00-080-002-A	Removal of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
TASK 27-00-00-480-002-A	Installation of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
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 27-50-00-480-802-A	Installation/Removal of the Check Pin at Track 1
TASK 27-50-00-860-801-A	Readout of the Flap Position Pickoff Unit (PPU) Data
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 27-51-00-820-001-A	Manual Adjustment of the Position Pick-Off Units
TASK 27-54-00-710-001-A	Operational Test of the Flap System
TASK 29-00-00-864-001-A	Put the Related Hydraulic System in the Depressurized Configuration before Maintenance Action
TASK 29-10-00-863-001-A	Pressurize the Green Hydraulic System with a Hydraulic Ground Power-Cart
TASK 29-10-00-863-002-A	Pressurize the Yellow Hydraulic System with a Hydraulic Ground Power-Cart
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 29-14-00-614-002-A	Pressurization of the Hydraulic Reservoirs through the Ground Connector
TASK 29-14-00-614-002-A-01	Pressurization of the Hydraulic Reservoirs with the Auxiliary Power Unit (APU)
TASK 29-23-00-863-001-A	Pressurize the Green Hydraulic System from the Yellow Hydraulic System through the PTU with the Electric Pump
TASK 29-24-00-863-001-A	Pressurize the Yellow Hydraulic System with the Electric Pump
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
Power Control Unit of the Flap System
Power Control Unit of the Flap System - Electrical and Hydraulic Connections

3. Job Set-up
Subtask 27-54-51-860-053-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Make sure that the flaps are retracted to the 0 degree position (Ref. AMM TASK 27-50-00-866-009).
(2) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is installed on the slat/flap control lever (Ref. AMM TASK 27-00-00-480-002).
(3) Make sure, that the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT are installed at the left torque shaft (6206CM) and the right torque shaft (6256CM) (Ref. AMM TASK 27-50-00-400-003).
(4) Make sure that the Green and Yellow hydraulic systems are depressurized and put them in the maintenance configuration (Ref. AMM TASK 29-00-00-864-001).
(5) Make sure that the reservoirs of the Green and Yellow hydraulic systems are depressurized (Ref. AMM TASK 29-14-00-614-001).
(6) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the hydraulic systems.
(7) Make sure that the main doors of the main gear are open (Ref. AMM TASK 32-12-00-010-001).
(8) Make sure that the ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE is in position at the main gear main door opening.
(9) Make sure that the check pins are installed at the left and right flap tracks 1 (Ref. AMM TASK 27-50-00-480-802).
(10) Make sure that a CONTAINER 5 L (1.32 USGAL) is in position below the Power Control Unit (PCU) (1).

Subtask 27-54-51-860-053-B ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Make sure that the flaps are retracted to the 0 degree position (Ref. AMM TASK 27-50-00-866-009).
(2) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is installed on the slat/flap control lever (Ref. AMM TASK 27-00-00-480-002).
(3) Make sure that the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT are installed at the left torque shaft (6206CM) and the right torque shaft (6256CM) (Ref. AMM TASK 27-50-00-400-003).
(4) Make sure that the Green and Yellow hydraulic systems are depressurized and put them in the maintenance configuration (Ref. AMM TASK 29-00-00-864-001).
(5) Make sure that the reservoirs of the Green and Yellow hydraulic systems are depressurized (Ref. AMM TASK 29-14-00-614-001).
(6) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the hydraulic systems.
(7) Make sure that the main doors of the main gear are open (Ref. AMM TASK 32-12-00-010-001).
(8) Make sure that the ACCESS PLATFORM 3M (10 FT) is in position at the main gear main door opening.
(9) Make sure that the check pins are installed at the left and right flap tracks 1 (Ref. AMM TASK 27-50-00-480-802).
(10) Make sure that a CONTAINER 5 L (1.32 USGAL) is in position below the Power Control Unit (PCU) (1).

Subtask 27-54-51-865-051-A

B. 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 27-54-51-910-050-A

A. Preparation for the Installation
(1) To install the same Power Control Unit (PCU), clean the splined surfaces of the connections with Non Aqueous Cleaner-- Petroleum Based - (Material No.08BBB1) .
(2) Clean the mounting bushes and make sure that they are in a good condition.
(3) Apply Mineral Oil base Grease-Anti-Fretting Paste - (Material No.03FDB1) to the splines of the left input universal joint (10) and the right input universal joint (35).

Subtask 27-54-51-420-051-C

B. Installation of the Power Control Unit

CAUTION: USE A SECOND WRENCH TO APPLY COUNTERTORQUE TO THE UNION WHEN YOU DISCONNECT/CONNECT HYDRAULIC LINES ON UNIONS. IF YOU DO NOT USE THE SECOND WRENCH, THERE IS A RISK THAT YOU WILL LOOSEN OR TIGHTEN THE UNION TOO MUCH.

CAUTION: YOU MUST INSTALL HYDRAULIC TUBES WITH HYDRAULIC FLUID AS LUBRICANT.

(1) Install the PCU (1) on the fuselage fitting as follows:
(a) Put the PCU (1) in position and install the attachment bolt (30), the bush (21), the washer (20) and the nut (19).
(b) Attach the PCU (1) to the attachment rod assembly (3) with the bolt (5), the bushes (6), the washer (7) and the nut (9).
(c) Attach the adjustable rod assembly (4) to the PCU (1) and install the bolt (5), the bushes (6), the washer (7) and the nut (9).
(d) Put the bolt (31) through the attachment bolt (30) and install the washer (18) and the nut (17).
(e) Tighten the nut (17) and safety it with lockwire, corrosion-resistant steel, dia. 0.8 mm (0.032 in.).
(f) Tighten the nuts (9) and safety them with the new AIPC 27-54-03-04-050 COTTER PINS (8) or AIPC 27-54-83-03-110 COTTER PINS (8).
(2) At the bonding point continue as follows:
(a) Put the bonding jumper (40) in position.
(b) Attach the bonding jumper (40) with the washer (41) and the screw (42) (Ref. AMM TASK 20-28-00-912-802).
(c) Seal the screw (42) and the washer (41) with Polysulfide Sealant_General Purpose Brushable - (Material No.06AAA1) .
(d) Apply Coating_- Flexible Structure (Material No.04QAB2) (dyed blue) to the bonding point.
(3) Engage the left input universal joint (10) of the PCU (1) in the left input of the PCU.
(4) Engage the right input universal joint (35) of the PCU (1) in the right input of the PCU.
(5) Install the left torque shaft 6202CM (13) as follows:
(a) Put the torque shaft (13) in position.
(b) Make sure that the flange holes of the torque shaft (13) are in line with the flange holes of the input universal joint (10).
(c) If the flange holes of the torque shaft (13) are not in line with the flange holes of the input universal joint (10), continue as follows:
1 Remove the input universal joint (10).
2 Turn the input universal joint (10) by the number of splines necessary to put it in line.
3 Install the input universal joint (10).
(d) Install the bolts (12) to connect the torque shaft (13) to the input universal joint (10).
(e) Install the nuts (11) on the bolts (12).
(f) Examine the assembly of the input universal joint (10) as follows:
1 Measure dimension X. Dimension X must be a minimum of 6.5 mm (0.2559 in.).
2 Make sure that you can not see the indicator groove.
(g) If you can see the indicator groove continue as follows:
1 Measure all the related torque shafts, universal joints and gearboxes and refer to LIEBHERR technical data.
(h) TORQUE the nuts (11) to between 1.24 and 1.02 m.daN (109.73 and 90.27 lbf.in )

.
(i) Apply Corrosion Preventive Compound-- Soft Film System (Material No.12AGC2) to the nuts (11) and the bolts (12).
(6) Install the right torque shaft 6252CM (32) as follows:
(a) Put the torque shaft (32) in position.
(b) Make sure that the flange holes of the torque shaft (32) are in line with the flange holes of the input universal joint (35).
(c) If the flange holes of the torque shaft (32) are not in line with the flange holes of the input universal joint (35), continue as follows:
1 Remove the input universal joint (35).
2 Turn the input universal joint (35) by the number of splines necessary to put it in line.
3 Install the input universal joint (35).
(d) Install the bolts (12) to connect the torque shaft (32) to the input universal joint (35).
(e) Install the nuts (11) on the bolts (12).
(f) Examine the assembly of the input universal joint (35) as follows:
1 Measure dimension X. Dimension X must be a minimum of 6.5 mm (0.2559 in.).
2 Make sure that you can not see the indicator groove.
(g) If you can see the indicator groove continue as follows:
1 Measure all the related torque shafts, universal joints and gearboxes and refer to LIEBHERR technical data.
(h) TORQUE the nuts (11) to between 1.24 and 1.02 m.daN (109.73 and 90.27 lbf.in )

.
(i) Apply Corrosion Preventive Compound-- Soft Film System (Material No.12AGC2) to the nuts (11) and the bolts (12).
(7) Remove the blanking caps from the electrical connectors.
(8) Make sure that all the electrical connections are clean and in the correct condition.
(9) Connect the electrical connectors 3CN-A, 3CN-B, 24CV-A, 23CV-A, 27CV-B and 27CV-A.
(10) Install the clamps which connect the electrical leads to the PCU (1).
(11) Remove the blanks and the plugs from the line (52) ends and the PCU (1).
(12) Apply Phosphate Ester Hydraulic Fluid-General Power - - (Material No.02ABA1) to the threads of the line end-fittings.
(13) Connect the hydraulic lines (52) to the PCU (1).
(14) TORQUE the union nuts of the hydraulic lines (52) to between 5.9 and 5.4 m.daN (43.51 and 39.82 lbf.ft )

.
(15) Connect the case drain lines (59) and (60).
(16) TORQUE the union nuts of the case drain lines (59) and (60) to between 1.7 and 1.5 m.daN (12.54 and 11.06 lbf.ft )

.
(17) Connect the seal drain lines (45) and secure them with the TIE WRAP (46).

Subtask 27-54-51-860-052-A

C. Preparation for the Test
(1) Remove the check pins from the left and right flap tracks 1 (Ref. AMM TASK 27-50-00-480-802).
(2) Remove the 98D27504030001 LOCK-TORQUE SHAFT (FLAPS AND SLATS) WITH CLAMP-PIVOT from the left torque shaft (6206CM) and from the right torque shaft (6256CM) (Ref. AMM TASK 27-50-00-000-003).
(3) Pressurize the reservoirs of the Green and Yellow hydraulic systems (Ref. AMM TASK 29-14-00-614-002).
(4) Make sure that the level of the fluid in the reservoirs is correct. Add fluid as necessary (Ref. AMM TASK 12-12-29-611-001) or (Ref. AMM TASK 12-12-29-611-002).
(5) Pressurize the Green and the Yellow hydraulic systems (Ref. AMM TASK 29-10-00-863-001) or (Ref. AMM TASK 29-23-00-863-001) and (Ref. AMM TASK 29-24-00-863-001) or (Ref. AMM TASK 29-10-00-863-002).
(6) Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION (Ref. AMM TASK 27-00-00-080-002) from the slat/flap control lever.
(7) Remove the WARNING NOTICE(S).

Subtask 27-54-51-865-052-A

D. 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 27-54-51-710-050-A

E. 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).
(3) If the PPU data are not in the specified limits, do the adjustment of the applicable PPU (Ref. AMM TASK 27-51-00-820-001).
(4) Do the operational test of the flap system (Ref. AMM TASK 27-54-00-710-001).
(5) Examine the PCU and make sure that there are no leaks.

5. Close-up
Subtask 27-54-51-410-050-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the container from below the PCU (1).
(3) Close the main doors of the main gear (Ref. AMM TASK 32-12-00-410-001).
(4) Remove the access platform(s).

[Rev.10 from 2021] 2026.03.31 23:54:16 UTC