G.  Disconnect power unit body from crank.
(1)  Remove cotter pin, nut, and bolt.
H.  Remove power unit from airplane.
I.  Remove fittings at inlet and outlet ports, and install plugs in ports.
4.  Prepare Aileron Power Control Units for Installation
A.  Install unions in inlet and outlet ports on new unit. Use new O-rings lightly lubricated with hydraulic fluid.
B.  Check that new unit is filled with hydraulic fluid before installation.
C.  Cap unions to prevent loss of hydraulic fluid.
5.  Install Aileron Power Control Unit
A.  If used bolts, bushings, bearings or other components with wear limits are being installed, check for allowable wear (Ref. 27-11-101, I/C).
B.  Position actuator in place and install bolt, washer and nut attaching actuator housing to crank (Fig. 401). Tighten nut to 300 - 410 pound-inches. Install cotter pin.
C.  Swing reaction link and position actuator end rod between fork end of reaction link. Install bolt, washer and nut to secure safety link to reaction link.
D.  Secure reaction link by installing bolt, washers, and large nut. Tighten nut to 300 - 350 pound-inches.
E.  Install small nut and tighten to 170 - 250 pound-inches. Install cotter pin.
F.  Remove plugs from hydraulic hoses and caps covering unions on power control unit.
G.  Connect hydraulic hoses to actuator.
H.  Deleted.
CAUTION:  ROD IS A DUAL LOADPATH COMPONENT. INSPECT INNER AND OUTER RODS FOR DAMAGE PRIOR TO INSTALLATION. DO NOT TIGHTEN THE OUTER BOLT AFTER YOU TIGHTEN THE LOCKNUT. DAMAGE TO EQUIPMENT CAN RESULT.
I. Connect valve control rod to actuator valve lever, install dual loadpath bolt and washers.
(1)  
Visually inspect bolts for damage prior to installation.

(2)  
Tighten outer bolt to 45-60 pound-inches.

(3)  
Install locknut  with washer over end of inner bolt and tighten to 12-25 pound-inches.

(4)  
Install cotter pin.

580 
27-11-71 Page 404  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  May 01/99 

J. Install the protective boot (Fig. 401).
(1)
Place protective boot on aileron power control unit and input rod.

(2)
Secure inboard end of boot with two straps.

NOTE:  While securing outboard end of boot, make sure that boot and strap do not cause a preload in either direction on the valve input rod to avoid biased input.

(3)
Secure outboard end of boot with one strap.

K. Provide electrical power.
L. Provide system A and B hydraulic power (Ref 27-11-0).
M. Operate aileron control wheel to bleed system and check for leaks at actuator connections.
N. Adjust aileron power control unit (Ref 27-11-71, Adjustment/Test).
O. Remove systems A and B hydraulic power (Ref 27-11-0).
P. Determine whether there is any further need for electrical power; if not, remove power.
500 
May 01/98  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  27-11-71 Page 405 

AILERON POWER CONTROL UNIT - ADJUSTMENT/TEST
1.  Aileron Power Control Unit Adjustment
(1)  Rigging Pins Kit - F70207-3, -52, -61, or -84:
REF NO.  F70207-( )  DIAMETER (INCHES)  LENGTH (INCHES)  FUNCTION 
A/S-4  -11  0.309 - 0.311  6.7 + 0.25  AILERON BUS DRUM 

B.  Adjust Aileron Power Control Unit
(1)  
Position aileron control wheels and trim control wheel in neutral position.

(2)  
Position flight control system A and B switches located on the pilot's overhead panel to OFF.

(3)  
Insert rigging pin A/S-4 (Fig. 502).

(4)  
Check that valve lever on each power control unit is centered between stops (Detail B).

(5)  
If valve levers are not centered between stops, proceed as follows:

WARNING:  DO NOT REMOVE POWER CONTROL UNIT VALVE ROD WITH HYDRAULIC POWER ON.
(a)  Loosen two locknuts on valve rod and rotate adjusting sleeve (detail A) to center valve lever between stops.
NOTE:  Whenever a valve rod is being replaced, rod should be trial adjusted to meet dimensions specified in Detail A.
(6)
Remove rigging pin A/S-4.
(6a) Provide systems A and B hydraulic power (Ref 27-11-0 MP).

(7)  
Position flight controls system A switch to ON and flight controls system B switch to OFF.

(8)  
Check that rigging pin A/S-4 fits freely in lower bus drum, if not:

(a)  Remove rigging pin A/S-4.
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Feb 20/88  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  27-11-71 Page 501 
　
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