MAINTENANCE MANUAL

FLAPS - MAINTENANCE PRACTICES

1. General

A. This section contains the general procedures to restore or to reuse the

connector protection of the flap system.

B. These procedures should be carried out whenever any connector replacement

or any electrical wire attachment maintenance is required in the flap
system.

C. Over the harness to actuator connection interface is installed a

shrinkable sleeve or a shrinkable insulator. The procedures to install
this connection interface protection is presented in the actuator
removal/installation instructions.

2. Referenced Procedures

A. 27-50-07 - Inboard Flap Hydraulic Actuator - Removal/Installation.

B. 27-50-08 - Nacelle Flap Hydraulic Actuator - Removal/Installation.

C. 27-50-09 - Outboard Flap Hydraulic Actuator - Removal/Installation.

D. 06-44-00/1 - Wing (Major Zones 500 and 600) Access Doors and Panels -
Description and Operation.

E. 20-00-00 - Wiring Manual - Standard Practices.

F. 27-51-00 - Wiring Manual - Flap System Electrical Diagram.

G. S.B. 120-27-0075 - Inspection of Wiring of Flap Actuator.

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3. Support Equipment

A. Heat gun - commercially available.

4. Material

A. Heat-shrinkable boot P/N 202A132-25/225 (RAYCHEM) - for inboard and/or

outboard flap harness connector.

B. Heat-shrinkable 90° boot P/N 222A132-25/225 (RAYCHEM) - for nacelle flap

harness connector.

C. Contact P/N MS3193A20-20A (TRI-STAR).

D. Sealant, specification MIL-S-8516, Type II, P/N PS-727 (RRC’S) or CS-3100

(CHEM SEAL) or equivalent.

NOTE: The material presented in A to D is applicable to connector P/N

MS3126 series.

E. Heat-shrinkable boot P/N 202D142-3/42 (RAYCHEM) for inboard and/or

outboard flap harness connector, if a replacement is required.

F. Heat-shrinkable boot P/N 222D142-3/86 (RAYCHEM) for nacelle flap harness

connector, if a replacement is required.

NOTE: The material presented in E and F is applicable to connector P/N

MS3467 series.

CAUTION: MAKE SURE THAT THE AIRPLANE IS SAFE FOR MAINTENANCE AND THAT THE
PWR SELECT SWITCH IS AT THE OFF POSITION.

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5. Connector P/N MS3126 Series Protection - Maintenance Procedures (Figure 201)

A. Protection removal

(1) Remove the protective shrinkable sleeve or shrinkable insulator and

disconnect the flap system connector (Ref. 27-50-07 or 27-50-08 or
27-50-09, as applicable).

(2) Remove the shrinkable boot.

(3) In case any electrical wire attachment repair or a connector

replacement is required, remove the potting mold and the sealant
from the connector back. Refer to 20-00-00 and 27-51-00 (Wiring
Diagrams) for repair or connector replacement.

B. Protection installation

(1) Inspect the connector for general conditions (corrosion,

contamination and contacts released from wires).

NOTE: In case a connector replacement is required, the use of

connector P/N MS3476 series is recommended. Refer to S.B.
120-27-0075.

(2) Clean the lengths of harness and the areas to be protected with
trichloroethylene. Care should be taken not to permit the solvent to
contact the connector nonmetallic parts.

(3) In case any electrical wire attachment or a replacement of the

connector with a new one bearing the same P/N has been carried out,
remake the protection on the connector back by using the potting
mold and sealant.

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Connector P/N MS3126 Series Protection

Figure 201

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NOTE: After the sealant application, the harness should remain
immobile for 30 minutes, after which it should be inspected
and finished by removing the excess sealant or filling the
voids, as required.

(4) Position the shrinkable boot over the potting mold as close to
connector as possible (1 mm).

(5) With the aid of the heat gun, heat-shrink the boot, always starting
at the connector and going in the direction of the harness.

(6) Position a new protective shrinkable sleeve or shrinkable insulator

over the harness.

(7) Connect connector to flap actuator and shrink the protective

shrinkable sleeve or shrinkable insulator over the connection
(actuator/harness connectors). Refer to MM 27-50-07 or 27-50-08 or
27-50-09, as applicable.

6. Connector P/N MS3476 Series Protection - Maintenance Procedures (Figures 202

and 203)

A. Protection boot removal

(1) Remove the protective shrinkable sleeve or shrinkable insulator and

disconnect the flap system connector (Ref. 27-50-07 or 27-50-08 or
27-50-09, as applicable).

(2) Displace the boot backwards according to steps 1 to 6 presented in

figure 203.

NOTE: A damaged boot should be replaced. In this case remove the

boot.

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B. Protection boot installation

(1) Inspect the connector for general conditions (corrosion,

contamination and contacts released from wires).

(2) In case a boot replacement is required, remove any residues of the

old adhesive and position a new boot in the harness. With the aid of
the heat-gun, heat-shrink the boot, always starting at the adapter
and going in the direction of the harness.

(3) For boot reuse, reinstall it according to steps 7 to 10 presented in

figure 203.

(4) Position a new protective shrinkable sleeve or shrinkable insulator

over the harness.

(5) Connect connector to flap actuator and shrink the protective

shrinkable sleeve or shrinkable insulator over the connection
(actuator/harness connectors). Refer to M.M. 27-50-07 or 27-50-08 or
27-50-09, as applicable.

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Connector P/N MS3476 Series Protection

Figure 202

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Procedures for Protection Boot Reuse

Figure 203

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