Krueger Flap - Removal/Installation Warning: Flight Controls - Make Sure That the Ground Safeties and Notices Are in Position

KRUEGER FLAP - REMOVAL/INSTALLATION WARNING: FLIGHT CONTROLS - MAKE SURE THAT THE GROUND SAFETIES AND NOTICES ARE IN POSITION. FLIGHT CONTROLS - MAKE SURE THAT THE TRAVEL RANGES OF THE CONTROL SURFACES ARE CLEAR. HYDRAULICS - BEFORE PRESSURIZING, MAKE SURE THAT THE CONTROLS MATCH THE SURFACE POSITION. ELECTRICAL POWER - BEFORE POWER IS SUPPLIED TO THE AIRCRAFT MAKE SURE THAT ANY ELECTRICAL CIRCUIT UPON WHICH WORK IS IN PROGRESS IS ISOLATED. 1. Reason for the Job A. Removal/Installation of the hinged door. B. Removal/Installation of the folding nose only. C. Removal/Installation of the Krueger flap and folding nose. D. Removal/Installation of the flight control rod. 2. Hinged Door A. Equipment and Materials

ITEM DESIGNATION

A. Access Platform 4 m (13 ft)

B. Circuit Breaker Safety Clips and Tags

C. Torque Wrench, 31 to 40 lbf.in. (0.35 - 0.45 m.daN)

D. Torque Wrench, 75 to 90 lbf.ft (10.17 to 12.20 m.daN)

E. Warning Notices Prohibiting Use of Slats and Krueger Flap Systems

F. SL90.313-0.8750 Installation Tool

G. SL90.314-0.8750 Removal Tool

H. SL90.374-0.8750 Wrench Tool

J. 98A27808011000 Rigging Pin - Krueger Flap

K. Cotter Pins

L. Material No. 04-004 Common Greases (Ref. 20-31-00)

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 1 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 ITEM DESIGNATION

Referenced Procedures

- (Ref. 20-21-16, P. STA LOK Nuts and Lockwashers Block 001)

List of Materials Required for Aircraft - (Ref. 20-31-00, P. Service and Maintenance Block 001)

- (Ref. 24-41-00, P. AC External Power Control Block 301)

- (Ref. 29-10-00, P. Main Hydraulic Power Block 301)

- (Ref. 29-21-00, P. Green Auxiliary Power Block 301)

B. Procedure (1) Job Set-Up (a) Energize the aircraft electrical network (Ref. 24-41-00, P. Block 301) . (b) Pressurize the Green hydraulic system (Ref. 29-21-00) or (Ref. 29-10-00, P. Block 301) . WARNING: IF THE SELECTOR SOLENOID IS USED TO EXTEND THE KRUEGER FLAP IT WILL CAUSE THE AILERON TO DROOP BY 10 DEGREES. NOTE: If the position of the slats is 15 deg. or greater, the Krueger flaps will already be extended. (c) On the Krueger selector solenoid-valve (50CV), at STA 2612/FR47, push (in) the button II on the solenoid II to extend the Krueger flap. (d) Open, safety and tag the circuit breakers that follow:

PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/SLATS Line 704

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 2 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/KRUEGER 45CV 704/M62

127VU FLT CTL/FLAPS Line 705

127VU FLT CTL/FLAPS & SLATS POS Line 705

127VU FLT CTL/SLATS Line 704

127VU FLT CTL/KRUEGER 45CV 704/M61

127VU FLT CTL/FLAPS Line 705

127VU FLT CTL/FLAPS & SLATS POS Line 705

(e) Display the warning notices, prohibiting the use of the slats and the Krueger flap systems. (f) Put the access platform in position below Zone 513 (613). (g) Engage the rigging pin PN 98A27808011000 through the Rib 2B and the outboard bracket. (2) Removal (Ref. Fig. 401) (Ref. Fig. 402) (a) Hold the Krueger flap, then use the removal tool PN SL90.314-0.8750 to remove the lockwasher (37) and use the wrench tool PN SL90.374-0.8750 to remove the nut (38) (Ref. 20-21-16, P. Block 001) . (b) Remove the bolt (35) from the outboard bracket and the actuator rod eye-end (36). Lower the Krueger flap and allow it to hang in approximately the mid- travel position. Remove and retain the sliding bushes (34). (c) Manually move the Krueger flap to get access to the hinged door pivotbolt (4) and bolt (9) positions. (d) Remove the cotter-pins (7), the nuts (6), the washers (5) and the bolts (9) that attach the door links (8) to the outboard brackets. Discard the cotter-pins (7).

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 3 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (e) Remove the cotter-pins (1), the nuts (2), the washers (3) and the bolts (4) that attach the door hinge assemblies to Ribs 2A and 2B. Discard the cotter-pins (1). (f) Remove the hinged door. (3) Installation (Ref. Fig. 401,402) (Ref. Fig. 403) (Ref. Fig. 404) (a) Manually move the Krueger flap to get access to the hinged door pivot-bolt (4) and (9) positions. Apply a layer of grease (Material No. 04-004) to the hinged door pivot-bolts (4) and put the hinged door in position, between the Ribs 2A and 2B. Install the hinged door with the pivot-bolts (4), the washers (3) and the nuts (2). Safety with new cotter-pins (1). Make sure that the door moves freely about the hinge axis. (b) Engage the eye-ends of the door link (8) onto the outboard bracket. Apply a layer of grease (Material No. 04-004) to the bolts (9). Install the bolts (9), the washers (5) and the nuts (6), to the outboard bracket (c) TORQUE the nuts (6) to between 31 and 40 lbf.in (0.35 and 0.45 m.daN) and safety with new cotter- pins (7). (d) Manually move the Krueger flap and align the actuator rod eye-end (36) with the outboard bracket assy. Apply a layer of grease (Material No. 04-004) to the sliding bushes (34) and the bolt (35). Install the sliding bushes (34) in the outboard bracket assy then install the bolt (35) through the inboard lug of the outboard bracket assy and the actuator rod eye-end (36). CAUTION: THE BOLT (35) HEAD MUST BE ON THE INBOARD LUG OF THE OUTBOARD BRACKET ASSY. (e) Install the nut (38) and use the wrench tool PN SL90.374-0.8750 to TORQUE the nut (38) to between

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 4 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 75 and 90 lbf.ft (10.17 and 12.20 m.daN) (Ref. 20-21-16, P. Block 001) . (f) Install the lockwasher (37) then use the installation tool PN SL90.313-0.8750 to lock the lockwasher (37) (Ref. 20-21-16, P. Block 001) . WARNING: IF THE SELECTOR SOLENOID IS USED TO RETRACT THE KRUEGER FLAP, IT WILL CAUSE THE AILERON TO RISE BY 10 DEGREES. (g) Make sure that the into and out-of-wind tolerances are correct (Ref. Fig. 403,404) . If necessary, remove the screws (10) and the door skin (for access). Adjust the shims as applicable, then install the door skin with the screws (10). (4) Preparation for test (a) Remove the safety clips and tags and close the SLATS and KRUEGER circuit breakers on panel 127VU, line 704. (5) Test (a) Do the test that follows:

ACTION RESULT

1. On the flight compartment center-pedestal:

The Krueger flap, the folding nose and the hinged -Put the slat and flap door operate and extend smoothly and lock in the ontrol-lever in extended position. position 15 (gate 2).

The Krueger flap, the folding nose and the hinged -Put the slat and flap door operate and etract smoothly and lock in the control-lever in closed position, with the Krueger flap and the position 0 (gate 1). hinged door in wing alignment.

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 5 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (6) Close-up (a) Depressurize the Green hydraulic system (Ref. 29-21-00) or (Ref. 29-10-00, P. Block 301) . (b) De-energize the aircraft electrical network (Ref. 24-41-00, P. Block 301) . (c) Remove the safety clips and tags and close the FLAPS circuit breakers on panel 127VU, line 705. (d) Remove the warning notices. (e) Remove the access platform. (f) Make sure that the work area is clean and clear of tools and miscellaneous items of equipment. 3. Folding Nose A. Equipment and Materials

ITEM DESIGNATION

A. Access Platform 4 m (13 ft)

B. Circuit Breaker Safety Clips and Tags

C. Torque Wrench 12 to 22 lbf.ft (1.6 to 3.0 m.daN)

D. Warning Notices Prohibiting Use of Slats and Krueger Flap Systems

E. SL90.313-0.4375 Installation Tool

F. SL90.314-0.4375 Removal Tool

G. SL90.374-0.4375 Wrench Tool

H. 98A27808011000 Rigging Pin - Krueger Flap

J. Cotter Pins

K. Material No. 04-004 Common Greases (Ref. 20-31-00, P. Block 001)

Referenced Procedures

- (Ref. 20-21-16, P. STA LOK Nuts and Lockwashers Block 001)

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 6 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 ITEM DESIGNATION

- (Ref. 20-28-11, P. Electrical Bonding Block 001)

List of Materials Required for Aircraft - (Ref. 20-31-00, P. Service and Maintenance Block 001)

- (Ref. 24-41-00, P. AC External Power Control Block 301)

- (Ref. 29-10-00, P. Main Hydraulic Power Block 301)

- (Ref. 29-21-00, P. Green Auxiliary Power Block 301)

PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/SLATS Line 704

127VU FLT CTL/KRUEGER 45CV 704/M62

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 7 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/FLAPS Line 705

127VU FLT CTL/FLAPS & SLATS POS Line 705

127VU FLT CTL/SLATS Line 704

127VU FLT CTL/KRUEGER 45CV 704/M61

127VU FLT CTL/FLAPS Line 705

127VU FLT CTL/FLAPS & SLATS POS Line 705

(e) Display the warning notices, prohibiting the use of the slats and the Krueger flap systems. (f) Put the access platform in position below Zone 513 (613). (g) Engage the rigging pin PN 98A27808011000 through the Rib 2B and the outboard bracket. (2) Removal (Ref. Fig. 401) (Ref. Fig. 405) (a) During removal of the folding nose assembly, to prevent damage to the seal (26), remove the nuts (22), the bolts (23), the reinforcing strip (24) and the seal (26). (b) Use the removal tool PN SL90.314-0.4375 to remove the lockwasher (15) and then use the wrench tool PN SL90.374-0.4375 to remove the nut (16). (c) Hold the folding nose assembly and remove the bolt (18). Make sure that the flight control rod (19), of the folding nose, hangs clear of the control- rod attachment-bracket (17). (d) Remove the nut (25), the washer (20) and the bolt (21), and disconnect the bonding lead from the folding nose structure. (e) Hold the folding nose assembly and remove the cotter-pin (27), the nut (28), the washers (29) and the bolt (30), at all three hinge positions. Discard the cotter-pins (27).

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 8 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (f) Remove the folding nose assembly. (3) Installation (Ref. Fig. 401,405) (a) Put the hinge-lugs of the folding nose, in position in the forks of the Krueger flap. Temporarily install the bolts (30), in the outer hinges of the Krueger flap, with the washers (29) and the nuts (28). (b) Make sure that the folding nose moves freely about the hinge axis. NOTE: The maximum permitted misalignment of the nose hinge line at the center hinge station, is 1.0 mm (0.04 in), in any direction, with the bolts (30) fitted in the outer hinge(s). (c) Temporarily install the bolt (30), in the center hinge with the washers (29) and the nut (28). (d) Manually lift the folding nose to the normally extended position. Make sure that there is a gap of 1.2 ± 0.5 mm (0.048 ± 0.019 in) between the folding nose trailing-edge and the Krueger flap. (e) Remove the nuts (28), the washers (29) and the bolts (30), from all three hinge positions. (f) Install the seal (26) on the Krueger flap with the reinforcing strip (24), the bolts (23) and the nuts (22). (g) Apply a layer of grease (Material No. 04-004) to the bolts (30). Put the folding nose in position, to align with the Krueger flap and install the bolts (30), the washers (29) and the nuts (28), in all three hinge positions. Safety with new cotter-pins (27). (h) Put the flight-control-rod (19) in position and aligned, in the control-rod attachment-bracket (17). Apply a layer of grease (Material No. 04-004) to the bolt (18) and install the bolt (18) through the control-rod attachment-bracket (17) and the flight control rod (19). (j) Use the wrench tool PN SL90.374-0.4375 to install and TORQUE the nut (16) to between 12 and 22 lbf.ft (1.60 and 3.0 m.daN). Then use the

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 9 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 installation tool PN SL90.313-0.4375 to lock the lockwasher (15) (Ref. 20-21-16, P. Block 001) . (k) Attach the bonding lead to the folding nose structure with the nut (25), the washer (20) and the bolt (21) (Ref. 20-28-11, P. Block 001) . WARNING: IF THE SELECTOR SOLENOID IS USED TO RETRACT THE KRUEGER FLAP, IT WILL CAUSE THE AILERON TO RISE BY 10 DEGREES. (l) On the Krueger flap selector-solenoid I(50CV), at STA2612/FR 47, push (in) the button I and carefully retract the Krueger flap and the folding nose. Make sure that the clearance between the folding nose and the fixed structure of the Krueger box, is not less than 3.00 mm (0.118 in), during the retraction. (4) Preparation for test (a) Remove the safety clips and tags and close the SLATS and KRUEGER circuit breakers on panel 127VU, line 704. (5) Test (a) Do the test that follows:

ACTION RESULT

1. On the flight compartment center-pedestal:

The Krueger flap, the folding nose and the hinged -Put the slat and flap door operate and extend smoothly and lock in the ontrol-lever in extended position. position 15 (gate 2).

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 10 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (6) Close-up (a) Depressurize the Green hydraulic system (Ref. 29-21-00) or (Ref. 29-10-00, P. Block 301) . (b) De-energize the aircraft electrical network (Ref. 24-41-00, P. Block 301) . (c) Remove the safety clips and tags and close the FLAPS circuit breakers on panel 127VU, line 705. (d) Remove the warning notices. (e) Remove the access platform. (f) Make sure that the work area is clean and clear of tools and miscellaneous items of equipment. 4. Krueger Flap and Folding Nose A. Equipment and Materials

ITEM DESIGNATION

A. Access Platform 4 m (13 ft)

B. Circuit Breaker Safety Clips and Tags

C. Torque Wrench 35 to 44 lbf.in. (0.4 to 0.5 m.daN)

D. Torque Wrench 14.75 to 75.20 lbf.ft (2.0 to 10.2 m.daN)

E. Warning Notices Prohibiting Use of Slats and Krueger Flap Systems

F. SL90.303-1.1250 Wrench Tool

G. SL90.309-1.1250 Installation Tool

H. SL90.310-1.1250 Removal Tool

J. SL90.313-0.7500 Installation Tool

K. SL90.313-0.8750 Installation Tool

L. SL90.314-0.7500 Removal Tool

M. SL90.314-0.8750 Removal Tool

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 11 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 ITEM DESIGNATION

N. SL90.374-0.7500 Wrench Tool

P. SL90.374-0.8750 Wrench Tool

Q. 98A27808011000 Rigging Pin - Krueger Flap

R. A0940000W2 Tool - Adjustment, Actuator Rod End

S. Brush

T. Lint-Free Cloth

U. Cotter Pins

V. Lockwire - Corrosion Resistant Steel, Dia. 0.032 in. (0.8 mm)

X. Material No. 04-004 Common Greases (Ref. 20-31-00, P. Block 001)

Y. Material No. 05-005 Special Materials (Ref. 20-31-00, P. Block 001)

Z. Material No. 09-013 Sealants (Ref. 20-31-00, P. Block 001)

AA. Material No. 11-004 Cleaning Agents (Ref. 20-31-00, P. Block 001)

Referenced Procedures

- (Ref. 20-21-16, P. STA LOK Nuts and Lockwashers Block 001)

- (Ref. 20-28-11, P. Electrical Bonding Block 001)

List of Materials Required for Aircraft - (Ref. 20-31-00, P. Service and Maintenance Block 001)

- (Ref. 24-41-00, P. AC External Power Control Block 301)

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 12 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 ITEM DESIGNATION

- (Ref. 27-89-11, P. Block 401)

- (Ref. 29-10-00, P. Position Switch - Krueger Extend Block 301)

- (Ref. 29-21-00, P. Block Main Hydraulic Power 301 ) Green Auxiliary Power

PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/SLATS Line 704

127VU FLT CTL/KRUEGER 45CV 704/M62

127VU FLT CTL/FLAPS Line 705

127VU FLT CTL/FLAPS & SLATS POS Line 705

127VU FLT CTL/SLATS Line 704

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 13 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/KRUEGER 45CV 704/M61

127VU FLT CTL/FLAPS Line 705

127VU FLT CTL/FLAPS & SLATS POS Line 705

(e) Display the warning notices, prohibiting the use of the slats and the Krueger flap systems. (f) Put the access platform in position below Zone 513 (613). (g) Engage the rigging pin PN 98A27808011000 through the Rib 2B and the outboard bracket. (2) Removal (Ref. Fig. 402) (Ref. Fig. 406) (a) Remove the hinged door (Ref. Para. 2.). (b) Remove the nut (70), the washer (69) and the bolt (68) and disconnect the bonding lead from the inboard hinge bracket. (c) Remove the Krueger-extend position-switch (Ref. 27-89-11, P. Block 401) . (d) Remove the bolts (46), the washers (47) and the cover plates (48) from the Ribs 2A and 2B. (e) Remove the bolts (60), the washers (61) and the cover plates (62) and (63) from the Rib 4. (f) Use the removal tool PN SL90.310-1.1250 to remove the lockwasher (42) from the bolt (49), at the outboard hinge. Then use the wrench tool PN SL90.303-1.1250 to loosen the nut (43) (Ref. 20-21-16, P. Block 001) . (g) Use the removal tool PN SL90.314-0.7500 to remove the lockwasher (64) from the bolt (71), at the outboard hinge. Then use the wrench tool PN SL90.374-0.7500 to loosen the nut (65) (Ref. 20-21-16, P. Block 001) . (h) Remove the cotter-pins (72), the nuts (73), the washers (74) and the bolts (75) from the control-

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 14 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 rod support assembly. Discard the cotter-pins (72). (j) Hold the Krueger flap and use the removal tool PN SL90.314-0.8750 to remove the lockwasher (37) from the bolt (35) of the outboard bracket. Then use the notched wrench PN SL90.374-0.8750 to remove the nut (38) (Ref. 20-21-16, P. Block 001) . (k) Remove the bolt (35) from the outboard bracket and the actuator-rod eye-end (36). Remove and retain the sliding bushes (34). (l) Remove the nut (43) from the hinge bolt (49), at Rib 2A and remove the washer (44). (m) Remove the nut (65) from the hinge bolt (71), at Rib 4 and remove the washer (66). (n) Remove the bolts (49) and (71) and the two fail safe bushes (45) and (67). Retain the two fail safe bushes (45) and (67). (p) Remove and retain the laminated washers (50) and record their position and dimension. (q) Remove the Krueger flap and folding nose assembly from the aircraft. (3) Installation (Ref. Fig. 402)

FED 410-414,419,422,427,429-430,434-436,442 (Ref. Fig. 407)

FED 401-405,407-409,416-418,420-421,423-426,428,431-433,443,445-499 (Ref. Fig. 408) (a) Put the Krueger flap in position on the wing. (b) Apply a layer of grease (Material No. 04-004) to the fail safe bush (67) and the bolt (71). Install the fail safe bush (67) and the bolt (71) through the Rib 4 and the inboard bracket of the Krueger flap. Install the washer (66), the nut (65) and the lockwasher (64). Do not lock at this stage.

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 15 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (c) Install the fail safe bush (45) and the bolt (49) through the Ribs 2A and 2B, and the outboard bracket of the Krueger-flap. (d) If a replacement Krueger flap is being fitted, center the flap as follows: 1) Measure the combined clearance between the Ribs 2A and 2B and the outboard bracket assembly. 2) Adjust the laminated washers (50), to take up the clearance. Make sure that the laminated washers (50) measure to within ± 1.5 mm (0.060 in) of each other. (e) Remove the fail safe bush (45) and the bolt (49), from the Ribs 2A and 2B. Apply a layer of grease (Material No. 04-004) to the fail safe bush (45) and the bolt (49). Put the applicable laminated washer (50) in position and install the fail safe bush (45) and the bolt (49). Apply a layer of special material (Material No. 05-005) to the washer (44). Install the washer (44), the nut (43) and the lockwasher (42) but, do not lock at this stage. (f) Apply a layer of special material (Material No. 05-005) to the bushes that are loosely installed on the control-rod support-assembly. Then apply a layer of grease (Material No. 04-004) to the bolts (75). (g) Install the bushes and the bolts (75), that have been treated, in the Ribs 2A and 2B and the control-rod support-assembly, with the washers (74) and the nuts (73). TORQUE the nuts (73) to between 62 and 71 lbf.in (0.7 and 0.8 m.daN) and safety with new cotter-pins (72). (h) Remove the rigging pin PN 98A27808011000 from Rib 2B and the outboard bracket. Manually move the Krueger flap over the full travel range, to make sure that the flap functions freely and without obstruction. (j) Fit the rigging pin PN 98A27808011000 through the Rib 2B and the outboard bracket (Krueger flap fully extended). (k) Apply a layer of grease (Material No. 04-004) to the sliding bushes (34) and the bolt (35). Put the

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 16 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 sliding bushes (34) in position, inside of each axle bearing, at Rib 2A and Rib 2B. (l) Make sure that the Krueger flap actuator is still fully retracted then align the actuator rod eye- end (36) with the outboard bracket. Install the bolt (35). If the bolt (35) cannot be fitted, adjust the actuator rod eye-end (36), as follows: 1) Cut, remove and discard the lockwire from the locknut (39). Use the tool PN A0940000W2 to loosen the locknut (39). Pull the lockwasher (40) clear and turn the actuator rod eye-end (36) thru steps of 180 deg. until the correct alignment is made. 2) If the 180 deg. progressive steps prove to be too large for easy installation of the bolt (35). Hold the actuator rod eye-end (36) tightly and turn the actuator rod thru 90 deg. to give a further adjustment of + 0.2 mm (0.008 in). (m) Engage the lockwasher (40) and turn the locknut (39) until it is finger tight. (n) Apply a layer of grease (Material No. 04-004) to the bolt (35). Install the bolt (35) through the outboard bracket and the actuator rod eye-end (36) then install the nut (38) and the lockwasher (37), but do not lock at this stage. (p) Remove the rigging pin PN 98A27808011000 from the Rib 2B and the outboard bracket. (q) Close the circuit breaker 45CV. WARNING: IF THE SELECTOR SOLENOID IS USED TO RETRACT THE KRUEGER FLAP, IT WILL CAUSE THE AILERON TO RISE BY 10 DEGREES. (r) On the Krueger flap selector-solenoid I(50CV), at STA2612/FR 47, push (in) the button I and carefully retract the Krueger flap. Make sure that the clearance between the folding nose and the fixed structure of the Krueger box, is not less than 3.00 mm (0.118 in), during the retraction. (s) Make sure that the Krueger flap is aligned with the wing and is within the into and out-of-wind tolerances (Ref. Fig. 403,404) .

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 17 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (t) Make sure that no contact occurs at the actuator, the mechanism, or the Krueger flap. (u) If the tolerances are not correct, adjust the Krueger flap as follows:

1) FED 401-405,407-409,416-418,420-421,423-426,428,431-433,443,445-499 Close the circuit breaker 45CV.

2) Fully extend the Krueger flaps (Ref. Para. 3. A. (3))

3) Open, safety and tag the circuit breaker 45CV.

4) Loosen the bolts (76) and (78) at the inboard and outboard brackets, carefully remove the shims (77) and (79). Adjust the shims (77) and (79) until, with the Krueger flap fully retracted, the tolerances are met.

5) TORQUE the bolts (76) and (78), to 2 m.daN. (14.75 lbf.ft.).

1) Close the circuit breaker 45CV.

2) Fully extend the Krueger flaps (Ref. Para. 3. A. (3)).

3) Open, safety and tag the circuit breakers 45CV.

4) Cut, remove and discard the lockwire. Loosen the bolts (76) and (78) at the inboard and outboard brackets and carefully remove the shims (77) and (79). Adjust the shims (76) and (78) until, with the Krueger flap fully retracted, the tolerances are met.

5) TORQUE the bolts (76) and (78) to 2 m.daN (14.75 lbf. ft.).

6) Safety the bolts (76) and (78) to the inboard and outboard bracket, with lockwire. (v) Make sure there is continuous contact between the Krueger flap trailing-edge seal and the fixed structure of the Krueger box, with the Krueger

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 18 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 flap in the fully extended position. Make sure that the seal deflection is within 0 to 3 mm (0 to 0.118 in). (w) TORQUE the locknut (39), at the actuator rod eye- end (36), to between 73.7 and 75.2 lbf.ft. (10 and 10.2 m.daN) and safety the locknut (39) with lockwire. (x) Use the wrench tool PN SL90.374-0.8750 to TORQUE the nut (38) to between 55 and 69 lbf.ft (7.46 and 9.36 m.daN). Then use the installation tool PN SL90.313-0.8750 to lock the lockwasher (37) (Ref. 20-21-16, P. Block 001) . (y) Use the wrench tool PN SL90.303-1.1250 to TORQUE the nut (43), at Rib 2A, to between 105 and 127 lbf.ft (14.20 and 17.20 m.daN). Then use the installation tool PN SL90.309-1.1250 to lock the lockwasher (42) (Ref. 20-21-16, P. Block 001) . (z) Use the wrench tool PN SL90.374-0.7500 to TORQUE the nut (65), at Rib 4, to between 35 and 48 lbf.ft (4.75 and 6.51 m.daN). Then use the installation tool PN SL90.313-0.7500 to lock the lockwasher (64) (Ref. 20-21-16, P. Block 001) . (aa) Seal the heads of the assembled hinge bolts (49), (75) and the bolt (46), and the nut (43), as follows: 1) Use cleaning agent (Material No. 11-004) with a brush and a clean lint-free cloth, to thoroughly clean around the items that follow: -each bolt (75) -the adjacent structure on Ribs 2A and 2B. 2) Apply a fillet of sealant (Material No. 09-013) to form a cap around the head of each bolt (75) and on the adjacent structure on Ribs 2A and 2B. 3) Use cleaning agent (Material No. 11-004) with a brush and a clean lint-free cloth, to thoroughly clean around the assembled items that follow: -the bolt (49) -the nut (43) -the washer (44)

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 19 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 -the lockwasher (42) -the adjacent structure on the Ribs 2A and 2B. 4) Apply a fillet of sealant (Material No. 09-013) to form a cap around the head of the bolt (49), the nut (43), the washer (44) and the lockwasher (42) and on the adjacent structure at Ribs 2A and 2B. 5) Use cleaning agent (Material No. 11-004) with a brush and a clean lint-free cloth, to thoroughly clean around the area of the assembled lockwasher (64), at Rib 4. Then apply a fillet of the sealant (Material No. 09-013), to form a cap around the lockwasher (64), the nut (65), the washer (66) and on the adjacent structure at Rib 4. (ab) Install the cover plates (48) to the Ribs 2A and 2B with the washers (47) and the bolts (46). TORQUE the bolts (46) to between 35 and 44 lbf.in (0.4 and 0.5 m.daN). (ac) Install the cover plates (62) and (63) at Rib 4, with the washers (61) and the bolts (60). TORQUE the bolts (60) to between 35 and 44 lbf.in (0.4 and 0.5 m.daN). (ad) Attach the bonding lead to the inboard hinge bracket with the bolt (68), the washer (69) and the nut (70) (Ref. 20-28-11, P. Block 001) . (ae) Install the Krueger-extend position-switch (Ref. 27-89-11, P. Block 401) . (af) Install the hinged door (Ref. Para. 2). (4) Preparation for test (a) Remove the safety clips and tags and close the SLATS and KRUEGER circuit breakers on panel 127VU, line 704. (5) Test (a) Do the test that follows:

ACTION RESULT

1. On the flight compartment center-pedestal:

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 20 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 ACTION RESULT

The Krueger flap, the folding nose and the hinged -Put the slat and flap door operate and extend smoothly and lock in the ontrol-lever in extended position. position 15 (gate 2).

(5) Close-up (a) Depressurize the Green hydraulic system (Ref. 29-21-00) or (Ref. 29-10-00, P. Block 301) . (b) De-energize the aircraft electrical network (Ref. 24-41-00, P. Block 301) . (c) Remove the safety clips and tags and close the FLAPS circuit breakers on panel 127VU, line 705. (d) Remove the warning notices. (e) Remove the access platform. (f) Make sure that the work area is clean and clear of tools and miscellaneous items of equipment. 5. Flight Control Rod A. Equipment and Materials

ITEM DESIGNATION

A. Access Platform 4 m (13 ft)

B. Circuit Breaker Safety Clips and Tags

C. Torque Wrench 1.4 to 3.0 m.daN (10.3 to 22.0 lbf.ft)

D. Shim, 2.0 mm (0.08 in) Thick

E. SL90.313-0.4375 Installation Tool

F. SL90.314-0.4375 Removal Tool

G. SL90.374-0.4375 Wrench Tool

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 21 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 ITEM DESIGNATION

H. Lint-Free Cloth

J Tie-Wrap or equi (Ref. 20-31-00, P. Block 001) valent (quantity 2)

K. Material No. 04-004 Common Greases

L. Material No. 09-016 Sealants (Ref. 20-31-00, P. Block 001)

M. Material No. 11-004 Cleaning Agents (Ref. 20-31-00, P. Block 001)

Referenced Procedures

- (Ref. 20-21-16, P. STA LOK Nuts and Lockwashers Block 001)

List of Materials Required for Aircraft Service - (Ref. 20-31-00, P. and Maintenance Block 001)

- (Ref. 27-87-00, P. Krueger Flap Control Block 501)

- (Ref. 29-10-00, P. Main Hydraulic Power Block 301)

- (Ref. 29-21-00, P. Green Auxiliary Power Block 301)

B. Procedure (1) Job Set-Up (a) Open, safety and tag these circuit breakers:

PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/SLATS Line 704

127VU FLT CTL/KRUEGER 45CV 704/M62

127VU FLT CTL/SLATS Line 704

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 22 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 PANEL SERVICE IDENT. LOCATION

127VU FLT CTL/KRUEGER 45CV 704/M61

(b) Put the access platform in position below Zone 513 (613). (c) Remove the access panel 513PL (613PR). (2) Removal (Ref. Fig. 409) (a) Use the removal tool PN SL90.314-0.4375 to remove the lockwasher (3) (Ref. 20-21-16, P. Block 001) . (b) Use the wrench tool PN SL90.374-0.4375 to remove the nut (4) (Ref. AMM 20-21-16, P. Block 301) . (c) Remove the bolt (5) from the control rod support- assembly. (d) Use a tie-wrap to hold the flight control rod against the control rod support-assembly. (e) Pressurize the Green hydraulic system (Ref. 29-10-00) or (Ref. 29-21-00, P. Block 301) . (f) On panel 127VU, remove the safety clip and tag and close the circuit breaker 45CV. WARNING: IF THE SELECTOR SOLENOID IS USED TO EXTEND THE KRUEGER FLAP IT WILL CAUSE THE AILERON TO DROOP BY 10 DEGREES. CAUTION: MAKE SURE THE FLIGHT CONTROL ROD AND THE TIE-WRAP WILL NOT CONTACT THE FOLDING DOOR WHEN THE KRUEGER FLAP EXTENDS. DAMAGE COULD OCCUR IF THEY CONTACT THE FOLDING DOOR THE EXTENSION.DURING

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 23 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (g) Push (in) the LH manual pushbutton (solenoid II) on the Krueger flap selector-solenoid valve at STA 2612/FR47 and fully extend the Krueger flaps. (h) On panel 127VU, open, safety and tag the circuit breaker 45CV. (j) Depressurize the Green hydraulic system (Ref. 29-10-00) or (Ref. 29-21-00, P. Block 301) . (k) Cut and remove the tie-wrap from the flight control rod/control rod support assembly interface. (l) Use the removal tool PN SL90.314-0.4375 to remove the lockwasher (8) (Ref. 20-21-16, P. Block 001) . (m) Use the wrench tool PN SL90.374-0.4375 to remove the nut (7) (Ref. AMM 20-21-16, P. Block 301) . (n) Remove the bolt (6) and the flight control rod from the control rod bracket. (3) Preparation for installation (Ref. Fig. 409) (Ref. Fig. 410) CAUTION: DO NOT CLEAN THE ROD END BEARING SURFACES BECAUSE THIS WILL REMOVE THE GREASE. (a) Use the lint-free cloth and the cleaning agent (Material No. 11-004) to clean the control rod bracket, the control rod support-assembly and the bolts (5) and (6). CAUTION: MAKE SURE THAT THE ANGULAR POSITION OF THE ROD ENDS IS CORRECT BEFORE YOU INSTALL THE FLIGHT CONTROL ROD. THE ANGULAR POSITION OF THE ROD ENDS IS IMPORTANT. (b) If you are to install a new flight-control rod: 1) Make sure the angular position of the rod ends is correct. 2) Measure the distance between the rod end centers. If necessary, adjust the length of the flight control rod to get the nominal dimension given. If you adjust the length,

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 24 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 keep the angular position of the rod ends correct and do not lock the lock plate (2). (c) If you are to install the flight control rod you removed, examine the bearing in each of the rod ends. The bearings must rotate freely in their housings. If a bearing is seized or sticking, you must replace the complete flight-control rod and adjust it as detailed in step (b). (4) Installation (Ref. Fig. 409) (a) Lubricate the bolt (6) with the grease (Material No. 04-004). (b) Put the flight control rod in position on the control rod bracket. Make sure the lock plate (2) is positioned so that you can get to the locking tab through the access panel 513PL (613PR). (c) Attach the flight control rod to the control rod bracket with the bolt (6) and the nut (7). Use the wrench tool PN SL90.374-0.4375 to TORQUE the nut (7) to 1.6 to 3.0 m.daN (12 to 22 lbf.ft) (Ref. 20-21-16) , P, Block 1). (d) Install the lockwasher (8) with the installation tool PN SL90.313-0.4375 (Ref. 20-21-16, P. Block 001) . (e) Apply the sealant (Material No. 09-016) to the head of the bolt (6) and to the nut (7). (f) Use a tie-wrap to hold the flight control rod against the control rod support-assembly. (g) Pressurize the Green hydraulic system (Ref. 29-10-00) or (Ref. 29-21-00, P. Block 301) . (h) On panel 127VU, remove the safety clip and tag and close the circuit breaker 45CV. WARNING: IF YOU USE THE SELECTOR SOLENOID TO RETRACT THE KRUEGER FLAP IT WILL CAUSE THE AILERON TO RISE BY 10 DEGREES. CAUTION: MAKE SURE THE FLIGHT CONTROL ROD AND THE TIE-WRAP WILL NOT CONTACT THE FOLDING DOOR WHEN THE KRUEGER FLAP RETRACTS. DAMAGE COULD OCCUR IF THEY CONTACT THE FOLDING DOOR DURING THE RETRACTION.

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 25 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (j) Push (in) the RH manual pushbutton (Solenoid I) on the Krueger flap selector-solenoid valve at STA2612/FR 47, and fully retract the Krueger flaps. (k) On panel 127VU, open, safety and tag the circuit breaker 45CV. (l) Depressurize the Green hydraulic system (Ref. 29-10-00) or (Ref. 29-21-00, P. Block 301) . (m) Cut and remove the tie-wrap from the flight control rod/control rod support-assembly interface. (n) Lubricate the bolt (5) with the grease (Material No. 04-004). (p) Put the flight control rod in position on the control rod supportassembly. (q) Measure the distance the rod end must move to be correctly aligned with the control rod support- assembly. The distance must be a minimum of 1.5 mm (0.06 in). If the distance is less: 1) Loosen the lock nut (1). 2) Adjust the length of the flight control rod to get the correct distance. Do not tighten the lock nut (1). NOTE: With the Krueger flap retracted and the flight control rod disconnected, the folding nose is in contact with the Krueger box. The movement that is necessary to align the flight control rod with the control rod support-assembly sets the clearance between the folding nose and the Krueger box. (r) Attach the flight control rod to the control rod support-assembly with the bolt (5) and the nut (4). Use the wrench tool PN SL90.374-0.4375 to

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 26 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 TORQUE the nut (4) to 1.6 to 3.0 m.daN (12 to 22 lbf.ft) (Ref. 20-21-16) , P, Block 1). (s) If you adjusted the length of the flight control rod: 1) Install a 2 mm (0.08 in) shim between the rod end and the inboard lug of the control rod support-assembly. 2) TORQUE the lock nut (1) to 1.4 to 2.1 mdaN (10.3 to 15.5 lbf.ft). 3) Remove the shim from the control rod support- assembly. (t) Make sure the flight control rod is free to turn about the centerline. The flight control rod must turn approximately 4.5 degrees, which equals approximately 0.8 mm (0.031 in) measured at the outer surface of the flight control rod. (u) Pressurize the Green hydraulic system (Ref. 29-10-00) or (Ref. 29-21-00, P. Block 301) . (v) On panel 127VU, remove the safety clip and tag and close the circuit breaker 45CV. WARNING: IF THE SELECTOR SOLENOID IS USED TO EXTEND THE KRUEGER FLAP IT WILL CAUSE THE AILERON TO DROOP BY 10 DEGREES. (w) Push (in) the LH manual pushbutton (solenoid II) on the Krueger flap selector-solenoid valve at STA 2612/FR47, and fully extend the Krueger flaps. (x) On panel 127VU, open, safety and tag the circuit breaker 45CV. (y) Depressurize the Green hydraulic system (Ref. 29-10-00) or (Ref. 29-21-00, P. Block 301) . (z) Make sure the flight control rod is free to turn about the centerline. The flight control rod must turn approximately 4.5 degrees, which equals approximately 0.8 mm (0.031 in) measured at the outer surface of the flight control rod.

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 27 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 (aa) If you adjusted the flight control rod, safety the nut (1) with the lock plate (2). (ab) Install the lockwasher (3) with the installation tool PN SL90.313-0.4375 (Ref. 20-21-16, P. Block 001) . (ac) Apply the sealant (Material No. 09-016) to the head of the bolt (5) and to the nut (4). (ad) Remove the safety clips and tags and close the SLATS and KRUEGER circuit breakers on panel 127VU, lines 704 and 705. (5) Test (a) Do an operational test of the Krueger flaps (Ref. 27-87-00, P. Block 501) . Make sure the flight

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 28 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 control rod does not catch on the control rod bracket or the control rod support-assembly. (6) Close-Up (a) Install the access panel 513PL (613PR). (b) Remove the access platform. (c) Make sure that the work area is clean and clear of tools and miscellaneous items of equipment. FED ALL

Figure 401 Figure 401. Hinged Door - Installation Details(Sheet 1)

Figure 402 Figure 402. Krueger Flap and Folding Nose - Installation Details(Sheet 1)

Figure 403 Figure 403. Krueger Flap and Doors - Gaps(Sheet 1)

Figure 404 Figure 404. Krueger Flap and Doors - Gaps(Sheet 1)

Figure 405 Figure 405. Folding Nose - Installation Details(Sheet 1)

Figure 406 Figure 406. Krueger Flap and Folding Nose - Installation Details(Sheet 1)

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 34 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 FED 410-414,419,422,427,429-430,434-436,442

Figure 407 Figure 407. Krueger Flap and Folding Nose - Installation Details(Sheet 1) FED 410-414,419,422,427,429-430,434-436,442

P.Blk EFFECTIVITY: FED ALL 27-80-19-04 Page 35 of 38 Printed - Date: 11/29/2012 Time: 11:13:51 Copyright © 2012 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 16/2012 FED 401-405,407-409,416-418,420-421,423-426,428,431-433,443,445-499

Figure 408 Figure 408. Krueger Flap and Folding Nose - Installation Details(Sheet 1) FED 401-405,407-409,416-418,420-421,423-426,428,431-433,443,445-499

Figure 409 Figure 409. Flight Control Rod Installation(Sheet 1) FED ALL

Figure 410 Figure 410. Flight Control-Rod Dimensions(Sheet 1)