W DOC AIRBUS | AMM A320F

Installation of the Door Locking Mechanism

TASK 52-11-21-400-001-A
Installation of the Door Locking Mechanism

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.
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 5M (16 FT)- ADJUSTABLE
No specific
1
DYNAMOMETER 20 DAN (45 LBF) - PULL
No specific
AR
SHIM THICKNESS 0.2 MM (0.008 IN)
No specific
Torque wrench: range to between 0.17 and 0.15 m.daN (15.04 and 13.27 lbf.in ) T
No specific
Torque wrench: range to between 0.17 and 0.16 m.daN (15.04 and 14.16 lbf.in ) T
No specific
Torque wrench: range to between 0.4 and 0.2 m.daN (35.40 and 17.70 lbf.in ) T
No specific
Torque wrench: range to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T
No specific
Torque wrench: range to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in ) T
No specific
Torque wrench: range to between 0.45 and 0.35 m.daN (39.82 and 30.97 lbf.in ) T
No specific
Torque wrench: range to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T
No specific
Torque wrench: range to between 0.8 and 0.7 m.daN (70.80 and 61.95 lbf.in ) T
No specific
Torque wrench: range to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in ) T
No specific
Torque wrench: range to between 2.6 and 2.2 m.daN (19.17 and 16.22 lbf.ft ) T
98D52103006000
1
PIN - RIGGING, DOOR ADJUST
98DNSA20206060
1
RIGGING PIN
OR
OR
98DNSA20206080
1
RIGGING PIN
OR
OR
98DNSA20206120
1
RIGGING PIN
 B. Consumable Materials
REFERENCE
DESIGNATION
(Material No.03HBD9)
Synthetic Ester base Grease-General Purpose Low Temp -
(Material No.03JBA1)
Silicone base Grease-General Purpose - -
(Material No.03RBB1)
Cetyl Alcohol base Lubricant-Fasteners Water base -
(Material No.04EAC2)
Primer Polyurethane Paint_- Corrosion Inhibiting Structure
(Material No.04JME4)
Top Coat Polyurethane_- Grey Internal Structure
(Material No.05BAE1)
Threadlocking Adhesive-- Medium strength -
(Material No.06AAB1)
Polysulfide Sealant-General Purpose Fillet -
(Material No.06AEA1)
Polysulfide Sealant-Low Adhesion Brushable -
(Material No.06AEB2)
Polysulfide Sealant-Low Adhesion Fillet Structure
(Material No.06LCG9)
Non Hardening Jointing Putty-Medium Temp. Area - -
(Material No.08BAA9)
Non Aqueous Cleaner-General - -
(Material No.12ABE2)
Corrosion Preventive Compound-Water Displacing Oily Film System
(Material No.12ACC1)
Corrosion Preventive Compound-Heavy Duty Soft Film -
(Material No.14QFB1)
Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -
(Material No.14SBA1)
Textile-Lint free Cotton -
 C. Work Zones and Access Panels
ZONE/ACCESS
ZONE DESCRIPTION
831, 831AZ, 831BZ, 831CZ, 831DZ, 831EZ, 841, 841AZ, 841BZ, 841CZ, 841DZ, 841EZ
 D. Expendable Parts
FIG.ITEM
DESIGNATION
IPC-CSN
401
COTTER PIN
AIPC 52-11-01-04-150
450
COTTER PIN
AIPC 52-11-01-04-150
171
COTTER PIN
AIPC 52-11-11-02-010
205
COTTER PIN
AIPC 52-11-11-02-160
308
COTTER PIN
AIPC 52-11-11-02-160
97
COTTER PIN
AIPC 52-11-11-02-160
195
COTTER PIN
AIPC 52-11-11-02-480
294
COTTER PIN
AIPC 52-11-11-05-010
220
COTTER PIN
AIPC 52-11-11-06-010
71
COTTER PIN
AIPC 52-11-11-06-010
85
COTTER PIN
AIPC 52-11-11-07-010
68
COTTER PIN
AIPC 52-11-11-07-180
7
COTTER PIN
AIPC 52-11-11-07-180
101
COTTER PIN
AIPC 52-11-11-08-010
106
COTTER PIN
AIPC 52-11-11-08-050
134
LOCKWASHER
AIPC 52-11-11-08-370
6
COTTER PIN
AIPC 52-11-11-09-060
37
COTTER PIN
AIPC 52-11-11-09-200
45
COTTER PIN
AIPC 52-11-11-09-200
76
COTTER PIN
AIPC 52-11-11-09-200
401
COTTER PIN
AIPC 52-11-11-12-060
450
COTTER PIN
AIPC 52-11-11-12-060
321
COTTER PIN
AIPC 52-11-11-13-010
416
COTTER PIN
AIPC 52-11-11-13-010
549
COTTER PIN
AIPC 52-11-11-13-010
506
COTTER PIN
AIPC 52-11-11-13-170
420
COTTER PIN
AIPC 52-11-11-14-010
325
COTTER PIN
AIPC 52-11-11-14-150
301
COTTER PIN
AIPC 52-11-11-14-230
343
LOCKWASHER
AIPC 52-11-11-14-340
20
COTTER PIN
AIPC 52-11-11-18-010
401
COTTER PIN
AIPC 52-11-81-02-150
450
COTTER PIN
AIPC 52-11-81-02-150
171
COTTER PIN
AIPC 52-11-81-07-010
205
COTTER PIN
AIPC 52-11-81-07-160
308
COTTER PIN
AIPC 52-11-81-07-160
97
COTTER PIN
AIPC 52-11-81-07-160
195
COTTER PIN
AIPC 52-11-81-07-480
220
COTTER PIN
AIPC 52-11-81-09-010
71
COTTER PIN
AIPC 52-11-81-09-010
401
COTTER PIN
AIPC 52-11-81-13-060
450
COTTER PIN
AIPC 52-11-81-13-060
321
COTTER PIN
AIPC 52-11-81-14-010
416
COTTER PIN
AIPC 52-11-81-14-010
549
COTTER PIN
AIPC 52-11-81-14-010
506
COTTER PIN
AIPC 52-11-81-14-170
20
COTTER PIN
AIPC 52-11-81-15-010
602
COTTER PIN
AIPC 53-16-01-23-020
602
COTTER PIN
AIPC 53-16-81-23-100
 E. Referenced Information
REFERENCE
DESIGNATION
TASK 20-22-00-400-001-A
Installation of STA-LOK Nuts and Lockwashers
TASK 20-28-00-912-802-A
Electrical Bonding - General Maintenance Procedure
TASK 25-23-46-400-001-A
Installation of the Door Linings on the Forward Passenger/Crew Doors
TASK 25-62-44-400-006-A
Installation of the Left Escape-Slide Pack-Assembly
TASK 25-62-44-400-007-A
Installation of the Left-Hand Escape-Slide-Raft Pack-Assembly
TASK 25-62-44-400-802-A
Installation of the Right Escape-Slide Pack-Assembly
TASK 25-62-44-400-803-A
Installation of the Right-Hand Escape-Slide-Raft Pack-Assembly
TASK 52-10-00-080-001-A
Removal of the Passenger/Crew Door Ballast Weight (98D52103501000) for Escape Slide
TASK 52-10-00-080-001-B
Removal of the Passenger/Crew Door Ballast Weight (98D52103501000) for Escape Slide/Raft
TASK 52-10-00-410-001-A
Closing of the Passenger/Crew Door
TASK 52-10-00-860-001-A
Special Precautions before Work on the Passenger/Crew Door
TASK 52-10-00-860-002-A
Special Precautions after Work on the Passenger/Crew Door
TASK 52-11-21-220-001-A
Detailed Visual Inspection of the Door Locking Mechanism
TASK 52-11-21-820-001-A
Adjustment/Test of the Door Locking Mechanism of the FWD Passenger/Crew Door
TASK 52-11-31-400-001-A
Installation of the Lining Flap
TASK 52-71-00-820-002-A
Adjustment of the Proximity Switches of the Passenger/Crew Doors with the Doors Checking Tool
TASK 52-71-00-820-002-A-01
Adjustment of the Proximity Switches of the Passenger/Crew Doors with the ECAM Display Unit (DU)
TASK 56-31-11-400-002-A
Installation of the Window of the Forward Passenger/Crew Door
F Inner Control Handle
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
F Outer Control Handle
F Plate Assembly
F Outer Control Handle - Adjustment of the Handle Stop ** ON A/C NOT FOR ALL
F Gearbox ** ON A/C NOT FOR ALL
F Gearbox - Rod Connection
F Gearbox ** ON A/C NOT FOR ALL
F Lowering Shaft
F Safety Pin and Locking Hook
F Safety Pin Adjustment
F Locking Hook Adjustment
F Locking Shaft Mechanism
F Locking Shaft Mechanism-Adjustment
F Reducer Shaft Mechanism
F Reducer Shaft Mechanism-Adjustment
F Torsion Bar - Compensation Mechanism
F Compensation Mechanism Adjustment
F Upper and Lower Connection Links
F Upper and Lower Lifting Levers-Adjustment
F Release of the Compensation Mechanism
3. Job Set-up
Subtask 52-11-21-860-050-A
A. Aircraft Maintenance Configuration
   (1) Make sure that the ACCESS PLATFORM 5M (16 FT)- ADJUSTABLE is in position in front of passenger/crew door 831 or 841.
   (2) Make sure that the door lining and the insulation are removed.
   (3) Obey the special precautions before you start the work on the passenger/crew door (Ref. AMM TASK 52-10-00-860-001).
Subtask 52-11-21-865-058-A
B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:
PANELDESIGNATIONFINLOCATION
** ON A/C ALL
121VUEIS/SLIDES/ARM AND WARN/FLT15WNP11
121VUEIS/SLIDES/ARM AND WARN/GND13WNP10
121VUEIS/SDAC1 AND 2/DOOR/DET/PAX48WVP05
Subtask 52-11-21-110-050-A
C. Cleaning
   (1) Clean the component interfaces and the adjacent area.
   (2) If necessary, clean the components with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
   (3) Do an inspection of the component interfaces and the adjacent area.
   (4) Make sure that the parts retained from the removed component are clean and in the correct condition.
(Ref. AMM TASK 52-11-21-220-001)
4. Procedure
Subtask 52-11-21-420-050-A ** ON A/C NOT FOR ALL
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
A. Installation of the Inner Control Handle
F Inner Control Handle ** ON A/C NOT FOR ALL
   (1) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the axle (174) of the gearbox.
   (2) Put the inner control handle (173) in position on the axle (174) and make sure that the grooves are aligned.
   (3) Install the washer (170) and the nut (172).
   (4) TORQUE the nut (172) to between 0.4 and 0.2 m.daN (35.40 and 17.70 lbf.in ) T.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
   (5) Install the new AIPC 52-11-11-02-010 COTTER PIN (171).
   (6) If you must install a new axle (174), drill a hole with a diameter of 3 mm (0.12 in.) for the cotter pin installation.
   (7) Adjust the inner control handle as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
     (a) Put the inner control handle in the door-down position.
     (b) Remove the lockwire from the nut (254) and adjust the length of the eye bolt (251) until:
       1 The bellcrank (252) touches the stop (253).
       2 Position X1 is 41 +1 mm or -1 mm (1.61 +0.04 in. or -0.04 in.) when the inner control handle is in the fully down position.
     (c) TORQUE the nut (254) to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T.
     (d) Safety the nut (254) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (e) Make sure that clearance J1 is 1 -0 mm or +0.5 mm (0.04 +0.00 in. or +0.02 in.).
     (f) If clearance J1 is not in the tolerance, do the adjustment that follows:
       1 Adjust the thickness of the washers (257) and (259) not to adjust the length of the spring (258).
   (8) Adjust the friction point of the inner control handle as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
     (a) Put the stop assembly (260) in position and make sure that:
  • Clearance J3 is 0.5 mm (0.02 in.) minimum in relation to the ramp (262).
  • The ball goes in the ramp by 0.3 mm (0.01 in.) to 0.5 mm (0.02 in.) in relation to the ramp (262).
  • Clearance J7 is 4 -0.2 mm or +0.2 mm (0.16 -0.01 in. or +0.01 in.) in relation to the ramp (262).
     (b) Adjust the screw (261) to lock the inner control handle with a force of 10 daN (22.48 lbf) (friction point plus normal operation force).
Subtask 52-11-21-420-051-A ** ON A/C NOT FOR ALL
B. Installation of the Outer Control Handle
F Outer Control Handle ** ON A/C NOT FOR ALL
   (1) Make sure that the axle (191) is pushed.
   (2) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the housing of the axle (191) of the outer control handle (192).
   (3) Put the outer control handle (192) in position and make sure that the grooves are aligned.
   (4) Push the axle (191) in its housing.
   (5) Install the washer (193) and the nut (194).
   (6) TORQUE the nut (194) to between 0.4 and 0.2 m.daN (35.40 and 17.70 lbf.in ) T.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
   (7) Install the new AIPC 52-11-11-02-480 COTTER PIN (195).
   (8) If you must install a new axle (191), drill a hole with a diameter of 3 mm (0.12 in.).
   (9) Adjust the outer control handle as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
     (a) Close the door from the outside.
     (b) Apply a manual pressure on the handle flap (267) until it touches the stop (268).
     (c) Release the handle flap (267) and make sure that it goes back to its initial position.
     (d) Do steps (b) and (c) again five times.
     (e) Make sure that out-of-flushness J4 is 0 -0.5 mm or +0.5 mm (0.00 -0.02 in. or +0.02 in.).
     (f) If the clearance is not in the tolerance, change the out-of-flushness with the eccentric roller (263).
     (g) Make sure that clearance J2 is 0.1 -0 mm or +0.2 mm (0.00 +0.00 in. or +0.01 in.).
     (h) If clearance J2 is not in the tolerance, do the adjustment that follows:
       1 Remove the nuts (266) and the screws (264).
       2 Adjust the shim (265) to get the correct clearance.
       3 Install the nuts (266) and the screws (264).
       4 Tighten the screws (264).
     (i) Make sure that the handle flap (267) goes back to its initial position when you close the door from the outside.
     (j) Do steps (b) and (c) again.
     (k) If necessary, adjust the position of the stop (268) with the new adjustable washers (269).
     (l) Make sure that peripheral clearance J5 between the outer control handle and the door is 1.5 +1.0 mm or -0.5 mm (0.06 +0.04 in. or -0.02 in.).
     (m) If clearance J5 is not in the tolerance, adjust the position of the outer control handle. To do this, use a new adjustable spacer (270).
   (10) Install the plate assembly (181) as follows:
F Plate Assembly ** ON A/C NOT FOR ALL
     (a) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the contact surface of the plate assembly (181).
     (b) Put the plate assemby (181) in position.
     (c) Apply Polysulfide Sealant-General Purpose Fillet - (Material No.06AAB1) on the housing of the screws (182) and (184).
     (d) Install the washers (183) and the screws (182) and (184).
     (e) Tighten the screws (182) and (184).
     (f) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
Subtask 52-11-21-420-052-A ** ON A/C NOT FOR ALL
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
C. Installation of the Gearbox
F Gearbox ** ON A/C NOT FOR ALL
   (1) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the door structure that touches the bearing (212) and the gearbox assembly (214).
   (2) Install the bearing (212) on the gearbox assembly (214).
   (3) Install the bolt (213) and the nut (211).
   (4) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the spacer (226) that touches the door structure.
   (5) Put the spacer (226) in position.
   (6) Install the spacer (227), the washer (228) and the set of washers (202).
   (7) Adjust the gearbox as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
     (a) Adjust the set of washers (271) to get clearance J6 of 0.1 -0 mm or +0.1 mm (0.00 +0.00 in. or +0.00 in.).
   (8) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the stop (229) that touches the spacer (226).
   (9) Put the stop (229) in position.
   (10) Install the bolts (221) and the nuts (230).
   (11) Tighten the nuts (211) and (230).
   (12) Install the spacer (231).
   (13) Install the inner control handle (222) and the outer control handle (238).
   (14) Put the inner control handle (222) and the outer control handle (238) in the door-closed position.
   (15) Connect the rod (223) as follows:
F Gearbox - Rod Connection ** ON A/C NOT FOR ALL
F Gearbox ** ON A/C NOT FOR ALL
     (a) Install the 98D52103006000 PIN - RIGGING, DOOR ADJUST on the bellcrank (275) of the locking shaft mechanism (door-down position).
     (b) Cut and discard the lockwire from the nuts (276).
     (c) Loosen the nuts (276) and release the lockwashers (277).
     (d) Turn the barrel of the rod (223) to connect the rod.
     (e) Tighten the nuts (276).
     (f) Make sure that the lockwashers (277) are in the correct position.
     (g) Safety the nuts (276) and the lockwashers (277) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (h) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (234) and (235).
     (i) Install the bushes (234) and (235).
     (j) Install the washer (209), the bolt (210), the washer (203) and the nut (204).
     (k) TORQUE the nut (204) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (l) Install the new AIPC 52-11-11-02-160 COTTER PIN (205).
     (m) If you install a new bolt (210), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
     (n) Remove the 98D52103006000 PIN - RIGGING, DOOR ADJUST from the bellcrank (275).
   (16) Connect the rod (207) as follows:
F Gearbox - Rod Connection ** ON A/C NOT FOR ALL
F Gearbox ** ON A/C NOT FOR ALL
     (a) Install the 98D52103006000 PIN - RIGGING, DOOR ADJUST in the bellcrank (280) of the reducer shaft mechanism (door-down position).
     (b) Cut and discard the lockwire from the nuts (279).
     (c) Loosen the nut (279) and release the lockwashers (278).
     (d) Turn the barrel of the rod (207) to connect the rod.
     (e) Tighten the nuts (279).
     (f) Make sure that the lockwashers (278) are in the correct position.
     (g) Safety the nuts (279) and the lockwashers (278) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (h) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (233) and (232).
     (i) Install the bushes (233) and (232).
     (j) Install the washer (209), the bolt (210), the washer (203) and the nut (204).
     (k) TORQUE the nut (204) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (l) Install the new AIPC 52-11-11-02-160 COTTER PIN (205).
     (m) If you install a new bolt (210), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
     (n) Remove the 98D52103006000 PIN - RIGGING, DOOR ADJUST from the bellcrank (280).
   (17) Connect the rod (217) as follows:
F Gearbox - Rod Connection ** ON A/C NOT FOR ALL
     (a) Put the door in the up position.
     (b) Install the 98DNSA20206060 RIGGING PIN98DNSA20206080 RIGGING PIN98DNSA20206120 RIGGING PIN in the lowering shaft (293).
     (c) Install the hook (292) and make it touch the inner control handle (238).
     (d) Make sure that clearance J18 between the hook (292) and the inner control handle (238) is from 0.2 mm (0.01 in.) to 1 mm (0.04 in.).
     (e) If clearance J18 is not in the tolerance, adjust the hook (292) as follows:
       1 Remove and discard the cotter pin (294).
       2 Loosen the nut (295).
       3 Adjust the hook (292) to get the correct clearance.
       4 Tighten the nut (295).
       5 Install the new AIPC 52-11-11-05-010 COTTER PIN (294).
       6 If you install a new bolt (296), drill a hole with a diameter of 2 mm (0.08 in.) for the cotter pin installation.
     (f) Cut and discard the lockwire from the nuts (291).
     (g) Loosen the nuts (291) and release the lockwashers (290).
     (h) Turn the barrel of the rod (217) to connect the rod.
     (i) Tighten the nuts (291).
     (j) Make sure that the lockwashers (290) are in the correct position.
     (k) Safety the nuts (291) and the lockwashers (290) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (l) Install the spacer (236).
     (m) Install the washer (218), the bolt (216) and the nut (219).
     (n) TORQUE the nut (219) to between 0.17 and 0.16 m.daN (15.04 and 14.16 lbf.in ) T.
     (o) Install the new AIPC 52-11-11-06-010 COTTER PIN (220).
     (p) If you install a new bolt (216), drill a hole with a diameter of 1.8 mm (0.07 in.) for the cotter pin installation.
     (q) Remove the 98DNSA20206060 RIGGING PIN98DNSA20206120 RIGGING PIN98DNSA20206080 RIGGING PIN from the lowering shaft (293).
   (18) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
Subtask 52-11-21-420-050-B ** ON A/C NOT FOR ALL
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
D. Installation of the Inner Control Handle
F Inner Control Handle ** ON A/C NOT FOR ALL
   (1) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the axle (174) of the gearbox.
   (2) Put the inner control handle (173) in position on the axle (174) and make sure that the grooves are aligned.
   (3) Install the washer (170) and the nut (172).
   (4) TORQUE the nut (172) to between 0.4 and 0.2 m.daN (35.40 and 17.70 lbf.in ) T.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
   (5) Install the new AIPC 52-11-11-02-010 COTTER PIN (171) or the new AIPC 52-11-81-07-010 COTTER PIN (171).
   (6) If you must install a new axle (174), drill a hole with a diameter of 3 mm (0.12 in.) for the cotter pin installation.
   (7) Adjust the inner control handle as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
     (a) Put the inner control handle in the door-down position.
     (b) Remove the lockwire from the nut (269) and adjust the length of the eye bolt (251) until:
       1 The bellcrank (252) touches the stop (253).
       2 Position X1 is 41 +1 mm or -1 mm (1.61 +0.04 in. or -0.04 in.) when the inner control handle is in the fully down position.
     (c) TORQUE the nut (269) to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T.
     (d) Safety the nut (269) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (e) Make sure that clearance J1 is 1 -0 mm or +0.5 mm (0.04 +0.00 in. or +0.02 in.).
     (f) If clearance J1 is not in the tolerance, do the adjustment that follows:
       1 Adjust the thickness of the washers (268) and (266) not to adjust the length of the spring (267).
   (8) Adjust the friction point of the inner control handle as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
     (a) Put the stop assembly (260) in position and make sure that:
  • Clearance J3 is 0.5 mm (0.02 in.) minimum in relation to the ramp (262).
  • The ball goes into the ramp by 0.3 mm (0.01 in.) to 0.5 mm (0.02 in.) in relation to the ramp (262).
  • Clearance J7 is 4 -0.2 mm or +0.2 mm (0.16 -0.01 in. or +0.01 in.) in relation to the ramp (262).
     (b) Adjust the screw (261) to lock the inner control handle with a force of 10 daN (22.48 lbf) (friction point plus normal operation force).
Subtask 52-11-21-420-051-B ** ON A/C NOT FOR ALL
E. Installation of the Outer Control Handle
F Outer Control Handle ** ON A/C NOT FOR ALL
   (1) Make sure that the axle (191) is pushed.
   (2) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the housing of the axle (191) of the outer control handle (192).
   (3) Put the outer control handle (192) in position and make sure that the grooves are aligned.
   (4) Push the axle (191) in its housing.
   (5) Install the washer (193) and the nut (194).
   (6) TORQUE the nut (194) to between 0.4 and 0.2 m.daN (35.40 and 17.70 lbf.in ) T.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
   (7) Install the new AIPC 52-11-11-02-480 COTTER PIN (195) or the new AIPC 52-11-81-07-480 COTTER PIN (195).
   (8) If you must install a new axle (191), drill a hole with a diameter of 3 mm (0.12 in.).
   (9) Adjust the outer control handle as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
F Outer Control Handle - Adjustment of the Handle Stop ** ON A/C NOT FOR ALL
     (a) With the outer control handle (192) in the up position, make sure that:
  • The outer control handle (192) locks in the up position.
  • Clearance J9 is 3 +0 mm or +1 mm (0.12 +0.00 in. or +0.04 in.) minimum at the level of the outer control handle before the pin stop (242) touches the stop screw (241).
     (b) If clearance J9 is not in the tolerance, do the adjustment that follows:
       1 Adjust the length of the stop screw (241) until:
  • Clearance J9 between the outer control handle (192) and the door outer skin is 3 +0 mm or +1 mm (0.12 +0.00 in. or +0.04 in.) minimum.
  • The pin stop (242) touches the stop screw (241).
     (c) Close the door from the outside.
     (d) Apply a manual pressure on the handle flap (265) until it touches the stop (263).
     (e) Release the handle flap (265) and make sure that it goes back to its initial position.
     (f) Do steps (d) and (e) again five times.
     (g) Make sure that out-of-flushness J4 is 0 -0.5 mm or +0.5 mm (0.00 -0.02 in. or +0.02 in.).
     (h) If the clearance is not in the tolerance, change the out-of-flushness with the eccentric roller (264).
     (i) Make sure that clearance J2 is 0.1 -0 mm or +0.2 mm (0.00 +0.00 in. or +0.01 in.).
     (j) If clearance J2 is not in the tolerance, do the adjustment that follows:
       1 Remove the nuts (256) and the screws (257).
       2 Adjust the shim (258) to get the correct clearance.
       3 Install the nuts (256) and the screws (257).
       4 Tighten the screws (257).
     (k) Make sure that the handle flap (265) goes back to its initial position when you close the door from the outside.
     (l) Do steps (d) and (e) again.
     (m) If necessary, adjust the position of the stop (263) with the new adjustable washers (259).
     (n) Make sure that peripheral clearance J5 between the outer control handle and the door is 1.5 +1.0 mm or -0.5 mm (0.06 +0.04 in. or -0.02 in.).
     (o) If clearance J5 is not in the tolerance, adjust the position of the outer control handle. To do this, use a new adjustable spacer (270).
   (10) Install the plate assembly (181) as follows:
F Plate Assembly ** ON A/C NOT FOR ALL
     (a) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the contact surface of the plate assembly (181).
     (b) Put the plate assembly (181) in position.
     (c) Apply Polysulfide Sealant-General Purpose Fillet - (Material No.06AAB1) on the housings of the screws (182) and (184).
     (d) Install the washers (183) and the screws (182) and (184).
     (e) Tighten the screws (182) and (184).
     (f) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
Subtask 52-11-21-420-052-B ** ON A/C NOT FOR ALL
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
F. Installation of the Gearbox
F Gearbox ** ON A/C NOT FOR ALL
   (1) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the door structure that touches the bearing (212) and the gearbox assembly (214).
   (2) Install the bearing (212) on the gearbox assembly (214).
   (3) Install the bolts (213) and the nuts (211).
   (4) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the spacer (226) that touches the door structure.
   (5) Put the spacer (226) in position.
   (6) Install the spacer (227), the washer (228) and the set of washers (202).
   (7) Adjust the gearbox as follows:
F Inner and Outer Control Handles - Gearbox Adjustment ** ON A/C NOT FOR ALL
     (a) Adjust the set of washers (271) to get clearance J6 of 0.1 +0 mm or +0.1 mm (0.00 +0.00 in. or +0.00 in.).
   (8) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the stop (229) that touches the spacer (226).
   (9) Put the stop (229) in position.
   (10) Install the washers (230), the bolts (237) and the nuts (221).
   (11) Tighten the nuts (211) and (221).
   (12) Install the spacer (231).
   (13) Install the inner control handle (222) and the outer control handle (238).
   (14) Put the inner control handle (222) and the outer control handle (238) in the door-closed position.
   (15) Connect the rod (223) as follows:
F Gearbox - Rod Connection ** ON A/C NOT FOR ALL
F Gearbox ** ON A/C NOT FOR ALL
     (a) Install the 98D52103006000 PIN - RIGGING, DOOR ADJUST on the bellcrank (275) of the locking shaft mechanism (door-down position).
     (b) Cut and discard the lockwire from the nuts (276).
     (c) Loosen the nuts (276) and release the lockwashers (277).
     (d) Turn the barrel of the rod (223) to connect the rod.
     (e) Tighten the nuts (276).
     (f) Make sure that the lockwashers (277) are in the correct position.
     (g) Safety the nuts (276) and the lockwashers (277) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (h) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (234) and (235).
     (i) Install the bushes (234) and (235).
     (j) Install the washer (209), the bolt (210), the washer (203) and the nut (204).
     (k) TORQUE the nut (204) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (l) Install the new AIPC 52-11-11-02-160 COTTER PIN (205) or the new AIPC 52-11-81-07-160 COTTER PIN (205).
     (m) If you install a new bolt (210), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
     (n) Remove the 98D52103006000 PIN - RIGGING, DOOR ADJUST from the bellcrank (275).
   (16) Connect the rod (207) as follows:
F Gearbox - Rod Connection ** ON A/C NOT FOR ALL
F Gearbox ** ON A/C NOT FOR ALL
     (a) Install the 98D52103006000 PIN - RIGGING, DOOR ADJUST in the bellcrank (280) of the reducer shaft mechanism (door-down position).
     (b) Cut and discard the lockwire from the nuts (279).
     (c) Loosen the nut (279) and release the lockwashers (278).
     (d) Turn the barrel of the rod (207) to connect the rod.
     (e) Tighten the nuts (279).
     (f) Make sure that the lockwashers (278) are in the correct position.
     (g) Safety the nuts (279) and the lockwashers (278) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (h) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (233) and (232).
     (i) Install the bushes (233) and (232).
     (j) Install the washer (209), the bolt (210), the washer (203) and the nut (204).
     (k) TORQUE the nut (204) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (l) Install the new AIPC 52-11-11-02-160 COTTER PIN (205) or the new AIPC 52-11-81-07-160 COTTER PIN (205).
     (m) If you install a new bolt (210), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
     (n) Remove the 98D52103006000 PIN - RIGGING, DOOR ADJUST from the bellcrank (280).
   (17) Connect the rod (217) as follows:
F Gearbox - Rod Connection ** ON A/C NOT FOR ALL
F Gearbox ** ON A/C NOT FOR ALL
     (a) Put the door in the up position.
     (b) Install the 98DNSA20206060 RIGGING PIN98DNSA20206080 RIGGING PIN98DNSA20206120 RIGGING PIN in the lowering shaft (293).
     (c) Install the hook (292) and make it touch the inner control handle (238).
     (d) Make sure that clearance J18 between the hook (292) and the inner control handle (238) is from 0.2 mm (0.01 in.) to 1 mm (0.04 in.).
     (e) If clearance J18 is not in the tolerance, adjust the hook (292) as follows:
       1 Remove and discard the cotter pin (294).
       2 Loosen the nut (295).
       3 Adjust the hook (292) to get the correct clearance.
       4 Tighten the nut (295).
       5 Install the new AIPC 52-11-11-05-010 COTTER PIN (294).
       6 If you install a new bolt (296), drill a hole with a diameter of 2 mm (0.08 in.) for the cotter pin installation.
     (f) Cut and discard the lockwire from the nuts (291).
     (g) Loosen the nuts (291) and release the lockwashers (290).
     (h) Turn the barrel of the rod (217) to connect the rod.
     (i) Tighten the nuts (291).
     (j) Make sure that the lockwashers (290) are in the correct position.
     (k) Safety the nuts (291) and the lockwashers (290) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (l) Install the spacer (236).
     (m) Install the washer (218), the bolt (216) and the nut (219).
     (n) TORQUE the nut (219) to between 0.17 and 0.16 m.daN (15.04 and 14.16 lbf.in ) T.
     (o) Install the new AIPC 52-11-11-06-010 COTTER PIN (220) or the new AIPC 52-11-81-09-010 COTTER PIN (220).
     (p) If you install a new bolt (216), drill a hole with a diameter of 1.8 mm (0.07 in.) for the cotter pin installation.
     (q) Remove the 98DNSA20206060 RIGGING PIN98DNSA20206080 RIGGING PIN98DNSA20206120 RIGGING PIN from the lowering shaft (293).
   (18) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
Subtask 52-11-21-420-053-A
G. Installation of the Lowering Shaft
F Lowering Shaft
   (1) Put the lowering shaft (82) in position.
   (2) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the door that touches the plate (84).
   (3) Install the plate (84), the bolts (83) and the nuts (88).
   (4) TORQUE the nuts (88) to between 0.45 and 0.35 m.daN (39.82 and 30.97 lbf.in ) T.
   (5) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the surface that touches the lever (86).
   (6) Install the lever (86) and make sure that the grooves are aligned.
   (7) Install the bolt (87) and the nut (85).
   (8) Tighten the nut (85).
   (9) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the door that touches the bearing (79).
   (10) Put the bearing (79) in position.
   (11) Install the bolt (80) and the nuts (78).
   (12) TORQUE the nuts (78) to between 0.45 and 0.35 m.daN (39.82 and 30.97 lbf.in ) T.
   (13) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the surface of the lowering shaft (82) that touches the lever assembly (75).
   (14) Install the lever assembly (75) and make sure that the grooves are aligned.
   (15) Install the bolt (76) and the nut (77).
   (16) TORQUE the nut (77) to between 0.45 and 0.35 m.daN (39.82 and 30.97 lbf.in ) T.
   (17) Put the rod (74) in position.
   (18) Install the spacer (70), the bolt (81), the washer (73) and the nut (72).
   (19) TORQUE the nut (72) to between 0.17 and 0.16 m.daN (15.04 and 14.16 lbf.in ) T.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
   (20) Install the new AIPC 52-11-11-06-010 COTTER PIN (71) or the new AIPC 52-11-81-09-010 COTTER PIN (71).
   (21) If you must install a new bolt (81), drill a hole with a diameter of 1.8 mm (0.07 in.) for the cotter pin installation.
   (22) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
Subtask 52-11-21-420-055-B
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
H. Installation of the Safety Pin and the Locking Hook
F Safety Pin and Locking Hook
   (1) Make sure that the door is in the open position.
   (2) Connect the rod (33) as follows:
     (a) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (34) and (39).
     (b) Install the bushes (34) and (39), the rod (33), the washer (32) and the bolt (31).
     (c) Install the washer (35) and the nut (36).
     (d) TORQUE the nut (36) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (e) Install the new AIPC 52-11-11-09-200 COTTER PIN (37).
     (f) If you must install a new bolt (31), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (3) Install the safety pin (30) on the fitting (56) as follows:
     (a) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the part of the safety pin (30) that moves.
     (b) Install the safety pin (30) in its fitting (56).
     (c) Apply Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) on the surface of the fitting (56) that touches the door structure.
     (d) Put the fitting (56) in position on the door structure and remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
     (e) Install the washers (35) and the bolts (54) and (55).
     (f) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the thread of the bolts (54) and (55) before you install it.
     (g) Tighten the bolts (54) and (55).
   (4) Assemble the safety pin as follows:
     (a) Install the washer (29), the caps (28), (27) and (26), the washer (25) and the bolt (24).
     (b) Apply Threadlocking Adhesive-- Medium strength - (Material No.05BAE1) on the thread of the bolt (24) before you install it.
     (c) Do not tighten the bolt (24) until you adjust the locking pin (30).
   (5) Connect the rod (33) as follows:
     (a) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (38) and (40).
     (b) Install the bushes (38) and (40), the rod (33), the washer (42) and the bolt (41).
     (c) Install the washer (43) and the nut (44).
     (d) TORQUE the nut (44) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (e) Install the new AIPC 52-11-11-09-200 COTTER PIN (45).
     (f) If you must install a new bolt (41), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (6) Adjust the safety pin as follows:
F Safety Pin Adjustment
     (a) With the door in the up position:
  • Make sure that the safety pin protects the shoulder of the bush on the fitting (56).
  • Make sure that clearance J10 is 0 -0.3 mm or +0.3 mm (0.00 -0.01 in. or +0.01 in.).
     (b) With the door in the down position (door closed and locked):
  • Make sure that clearance J11 between the frame structure and the safety pin is 4 -1 mm or +1 mm (0.16 -0.04 in. or +0.04 in.).
     (c) If clearances J10 and J11 are not in the tolerances, open the door and adjust it as follows:
       1 Remove the bolt (24), the adjustable washers (25) and (29) and the caps (26), (27) and (28).
       2 Install the new adjustable washers (25) and (29) with the caps (26), (27) and (28) and the bolt (24).
       3 TORQUE the bolt (24) to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T.
   (7) Install the locking hook (2):
     (a) Install the locking hook as follows:
       1 Put the door in the up position.
       2 Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the part of the shouldered bush (4) that moves.
       3 Install the shouldered bush (4), bolt (15), washer (14) and nut (5).
       4 TORQUE the nut (5) to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in ) T.
       5 Install the new AIPC 52-11-11-09-060 COTTER PIN (6).
       6 If you must install a new bolt (15), drill a hole with a diameter of 2.7 mm (0.11 in.) for the cotter pin installation.
     (b) Connect the rod (48) as follows:
       1 Install the bellow (50), plate (51), bolts (52) and clamp (53) but do not tighten the clamp (53).
       2 TORQUE the nuts (49) to between 0.45 and 0.35 m.daN (39.82 and 30.97 lbf.in ) T.
       3 Install the bushes (10) and (11) with Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) , the washer (12) and the bolt (13).
       4 Install the washer (9) and the nut (8).
       5 TORQUE the nut (8) to between 0.8 and 0.7 m.daN (70.80 and 61.95 lbf.in ) T.
       6 Install the new AIPC 52-11-11-07-180 COTTER PIN (7).
       7 If you must install a new bolt (13), drill a hole with a diameter of 2 mm (0.08 in.) for the cotter pin installation.
     (c) Connect the rod (23) as follows:
       1 Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (21) and (22).
       2 Install the bushes (21) and (22), the washer (17) and the bolt (16).
       3 Install the washer (18) and the nut (29).
       4 TORQUE the nut (19) to between 0.17 and 0.15 m.daN (15.04 and 13.27 lbf.in ) T.
       5 Install the new AIPC 52-11-11-18-010 COTTER PIN (20) or the new AIPC 52-11-81-15-010 COTTER PIN (20).
       6 If you must install a new bolt (16), drill a hole with a diameter of 1.8 mm (0.07 in.) for the cotter pin installation.
   (8) Adjust the locking hook (52) as follows:
F Locking Hook Adjustment
     (a) Open the door.
     (b) Put the SHIM THICKNESS 0.2 MM (0.008 IN) in the upper fittings on the frame.
     (c) Close the door.
     (d) Make sure that clearance M1 between the locking hook (52) and the roller (58) is 0.5 +0.3 mm or -0.3 mm (0.02 +0.01 in. or -0.01 in.).
     (e) If clearance M1 is not in the tolerance, do as follows:
       1 Turn the rod (48) one turn to make it shorter.
       2 Remove and discard the cotter pin (602) and remove the nut (601).
       3 Pull out the bush (603) by 4 mm (0.16 in.) to disengage it from the stop flat (605).
       4 Turn the bush (603) to get the correct value -0.9, -0.6, +0.6, +1.5 or +1.2.
       5 Make sure that the bush (603) stays engaged in its slot in the eccentric yoke (604).
NOTE: The slotted drive between the bush (603) and the eccentric yoke (604) has a foolproofing device (one position only).
       6 Push the bush (603) until the correct value aligns with the mark of the stop flat (605).
       7 Install the nut (601) and tighten it.
       8 Turn the barrel of the rod (48) until the locking hook (52) touches the roller (58).
       9 Install the new AIPC 53-16-01-23-020 COTTER PIN (602) or the new AIPC 53-16-81-23-100 COTTER PIN (602).
       10 Tighten the nuts (46) and the clamp (53).
       11 Make sure that the lockwashers (47) are in the correct position.
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
       12 Safety the nuts (46) and the lockwashers (47) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (f) Open the door and remove the shims from the upper fittings (on the frame).
Subtask 52-11-21-420-056-A
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
I. Installation of the Locking Shaft
F Locking Shaft Mechanism
   (1) Make sure that the door is in the closed position.
   (2) Install the bearing assembly (110) as follows:
     (a) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the bearing assembly (110) that touches the door structure.
     (b) Install the bearing assembly (110), the bolts (111) and the nuts (109) and tighten them.
     (c) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
   (3) Install the bush (119) and the washer (118) on the upper locking shaft (117).
   (4) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the surface of the shaft upper locking (117).
   (5) Make sure that the grooves are aligned when you install the lever assemblies (122), (127) and (129) and the bellcrank assemblies (125) and (123) on the upper locking shaft (117).
   (6) Put the upper locking shaft (117) in position.
   (7) Install the washer (120) and the bush (121).
   (8) Install the bellcrank assembly (123) and the lever assembly (122).
   (9) Install the spacer (124).
   (10) Install the bellcrank assembly (125).
   (11) Install the lever assemblies (127) and (129) and the bushes (130) and (128).
   (12) Install the washer (108) and the nut (107).
   (13) If you install a new upper locking shaft (117), drill a hole with a diameter of 3.7 mm (0.15 in.) for the cotter pin installation.
   (14) TORQUE the nut (107) to between 2.6 and 2.2 m.daN (19.17 and 16.22 lbf.ft ) T.
   (15) Install the new AIPC 52-11-11-08-050 COTTER PIN (106).
   (16) Install the lever assembly (104), taper pin (105), washer (103) and nut (102) and tighten them.
   (17) Make sure that the grooves on the lever assembly (104) are aligned with the grooves on the upper locking shaft (117).
   (18) Install the new AIPC 52-11-11-08-010 COTTER PIN (101).
   (19) Connect the rod (67) as follows:
     (a) Put the rod (67) in position in its fitting.
     (b) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (61) and (65).
     (c) Install the bushes (61) and (65), the washer (66) and the bolt (90).
     (d) Install the washer (64) and the nut (62).
     (e) TORQUE the nut (62) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (f) If you must install a new bolt (90), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (20) Connect the rod (87) as follows:
     (a) Put the rod (87) in position in its fitting.
     (b) Install the bush (88), the bolt (89), the washer (86) and the nut (84).
     (c) TORQUE the nut (84) to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T.
     (d) Install the new AIPC 52-11-11-07-010 COTTER PIN (85).
     (e) If you must install a new bolt (89), drill a hole with a diameter of 2 mm (0.08 in.) for the cotter pin installation.
   (21) Connect the rod (80) as follows:
     (a) Put the rod (80) in position in its fitting.
     (b) Install the bushes (79) and (81), the washer (82) and the bolt (83).
     (c) Install the washer (78) and the nut (77).
     (d) TORQUE the nut (77) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (e) Install the new AIPC 52-11-11-09-200 COTTER PIN (76).
     (f) If you must install a new bolt (83), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (22) Install the 98D52103006000 PIN - RIGGING, DOOR ADJUST in the bellcrank assembly (125).
   (23) Connect the rod (92) as follows:
F Locking Shaft Mechanism
F Locking Shaft Mechanism-Adjustment
     (a) Cut and discard the lockwire from the nuts (142).
     (b) Loosen the nuts (142) and release the lockwashers (143).
     (c) Turn the barrel of the rod (92) to connect the rod.
     (d) Install the bushes (93) and (98) and the bolt (94).
     (e) Install the washer (95) and the nut (96) and tighten it.
     (f) Install the new AIPC 52-11-11-02-160 COTTER PIN (97) or the new AIPC 52-11-81-07-160 COTTER PIN (97).
     (g) If you must install a new bolt (94), drill a hole with a diameter of 2 mm (0.08 in.) for the cotter pin installation.
     (h) Tighten the nuts (142).
     (i) Make sure that the lockwashers (143) are in the correct position.
     (j) Safety the nuts (142) and the lockwashers (143) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
   (24) Adjust the upper stops as follows:
     (a) Make sure that the 98D52103006000 PIN - RIGGING, DOOR ADJUST is in position in the bellcrank assembly (125).
     (b) Make sure that the kinematic stop (132) of the bellcrank assembly (125) touches the door structure.
     (c) If it does not touch the door structure, adjust it as follows:
       1 Loosen the nut (133).
       2 Remove and discard the lockwasher (134).
       3 Remove the washer (135).
       4 Adjust the setscrew (136) until the kinematic stop (132) of the bellcrank assembly (125) touches the door structure.
       5 Apply Cetyl Alcohol base Lubricant-Fasteners Water base - (Material No.03RBB1) on the threads of the setscrew (136).
       6 Install the washer (135), the new AIPC 52-11-11-08-370 LOCKWASHER (134) and the nut (133).
       7 TORQUE the nut (133) to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in ) T.
       8 Safety the nut (133) with the lockwasher (134).
     (d) Put the lever assembly (122) in position until it touches the bellcrank assembly (123).
     (e) Make sure that clearance J6 is 0.5 +0 mm or +0.1 mm (0.02 +0.00 in. or +0.00 in.).
     (f) If clearance J6 is not in the tolerance, adjust it as follows:
       1 Loosen the nut (133).
       2 Remove and discard the lockwasher (134).
       3 Remove the washer (135).
       4 Adjust the setscrew (136) to get the correct clearance.
       5 Apply Cetyl Alcohol base Lubricant-Fasteners Water base - (Material No.03RBB1) on the threads of the setscrew (136).
       6 Install the washer (135), the new AIPC 52-11-11-08-370 LOCKWASHER (134) and the nut (133).
       7 TORQUE the nut (133) to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in ) T.
       8 Safety the nut (133) with the lockwasher (134).
   (25) Remove the 98D52103006000 PIN - RIGGING, DOOR ADJUST.
   (26) Connect the rod (75) as follows:
     (a) Put the rod (75) in position in its fitting.
     (b) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (71) and (72).
     (c) Install the bushes (71) and (72) with Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) , the washer (73) and the bolt (74).
     (d) Install the washer (70) and the nut (69).
     (e) TORQUE the nut (69) to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T.
     (f) Install the new AIPC 52-11-11-07-180 COTTER PIN (68).
     (g) If you must install a new bolt (74), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (27) Check and adjustment of the locking hook (138) (Ref. AMM TASK 52-11-21-820-001):
     (a) Open the door and put the SHIM THICKNESS 0.2 MM (0.008 IN) in the upper guide fittings.
     (b) Close the door.
     (c) Adjust the locking hook (138) as follows:
       1 Turn the barrel of the rod (75) until the locking hook (138) touches the roller (137).
       2 Tighten the nuts (139) and the clamp (147).
       3 Make sure that the lockwashers (140) are in the correct position.
       4 Safety the nuts (139) and the lockwashers (140) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
     (d) Open the door and remove the shims from the upper fittings.
   (28) Install the plate (113) as follows:
F Locking Shaft Mechanism
     (a) Install the set of washers (112) and put the plate (113) in position.
     (b) Make sure that clearance J8 is 0.3 +0 mm or +0.5 mm (0.01 +0.00 in. or +0.02 in.).
     (c) If clearance J8 is not in the tolerance, adjust the set of washers (112).
     (d) Install the set of washers (112), plate (113), bolts (114), washers (115) and nuts (116).
     (e) Tighten the nuts (116).
   (29) Adjust the visual indicator as follows:
F Locking Shaft Mechanism
     (a) Make sure that the emergency control handle is in the DISARMED position.
     (b) Put the inner control handle in the door down-locked position.
     (c) Make sure that the boundary line between the red and green zones of the lever (129) is aligned with the upper edge of the indicator plate (113).
     (d) If it is not aligned, adjust the boundary line as follows:
       1 Loosen the stop (146) to make it align.
       2 TORQUE the stop (146) to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in ) T.
     (e) Put the emergency control handle in the ARMED position and make sure that clearance J7 between the hook (138) and the emergency control handle is 2 +0 mm or +0.5 mm (0.08 +0.00 in. or +0.02 in.).
     (f) If the clearance is not in the tolerance, adjust the rod (67) as follows:
       1 Cut and discard the lockwire from the nuts (144).
       2 Loosen the nuts (144) and release the lockwashers (145).
       3 Turn the barrel of the rod (67) until you get clearance J7. The lever (129) must touch the lever (127).
       4 Tighten the nuts (144).
       5 Make sure that the lockwashers (145) are in the correct position.
       6 Safety the nuts (144) and the lockwashers (145) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
   (30) Do an adjustment of proximity switch 13WV1 or 13WV2 (Ref. AMM TASK 52-71-00-820-002).
Subtask 52-11-21-420-057-A
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
J. Installation of the Reducer Shaft
F Reducer Shaft Mechanism
   (1) Make sure that the door is closed and locked.
   (2) Apply Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) on the contact surface of the bearing assembly (305) with the door structure.
   (3) Install the bearing assembly (305), fitting (335), bolts (304) and nuts (306).
   (4) Tighten the nuts (306).
   (5) Put the shaft (330) in position and install the washer (329), the bellcranks (331), (332) and (333) and the spacer (334).
   (6) Make sure that the grooves on the bellcranks (331), (332) and (333) are aligned.
   (7) Apply Polysulfide Sealant-Low Adhesion Fillet Structure (Material No.06AEB2) on the contact surface of the bearing assembly (327) with the door structure.
   (8) Install the bearing assembly (327), the bolts (323) and the nuts (324).
   (9) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
   (10) Install the washers (303), nuts (302), washers (327) and nuts (326).
   (11) TORQUE the nuts (302) and (326) to between 0.4 and 0.2 m.daN (35.40 and 17.70 lbf.in ) T.
   (12) Install the new AIPC 52-11-11-14-230 COTTER PIN (301) and the new AIPC 52-11-11-14-150 COTTER PIN (325).
   (13) If you must install a new shaft (330), drill a hole with a diameter of:
  • 2.8 mm (0.11 in.) for the installation of the cotter pin (301).
  • 3.7 mm (0.15 in.) for the installation of the cotter pin (325).
   (14) Install the 98D52103006000 PIN - RIGGING, DOOR ADJUST in the fitting (306) and in the bellcrank (333).
   (15) Connect the rod (310) as follows:
F Reducer Shaft Mechanism-Adjustment
     (a) Cut and discard the lockwire from the nuts (341).
     (b) Loosen the nuts (341) and release the lockwashers (340).
     (c) Turn the barrel of the rod (310) to adjust its length.
     (d) Tighten the nuts (341).
     (e) Make sure that the lockwashers (340) are correctly installed.
     (f) Safety the nuts (341) and the lockwashers (340) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
   (16) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (311) and (312).
   (17) Install the bushes (311) and (312), the washer (313) and the bolt (314).
   (18) Install the washer (309) and the nut (307).
   (19) TORQUE the nut (307) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
   (20) Install the new AIPC 52-11-11-02-160 COTTER PIN (308) or the new AIPC 52-11-81-07-160 COTTER PIN (308).
   (21) If you install a new bolt (314), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (22) Connect the rod (317) as follows:
     (a) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (318) and (319).
     (b) Install the bushes (318) and (319), the washer (316) and the bolt (315).
     (c) Install the bushes (320) and the nut (322).
     (d) TORQUE the nut (322) to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T.
     (e) Install the new AIPC 52-11-11-13-010 COTTER PIN (321) or the new AIPC 52-11-81-14-010 COTTER PIN (321).
     (f) If you must install a new bolt (315), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (23) Remove the 98D52103006000 PIN - RIGGING, DOOR ADJUST from the fitting (306) and the bellcrank (333).
   (24) Open the door (door in the up position).
   (25) Install the 98D52103006000 PIN - RIGGING, DOOR ADJUST in the fitting (306) and the bellcrank (333).
   (26) Make sure that the stop (347) installed on the bellcrank (333) touches the door structure.
   (27) If it does not touch the door structure, adjust it as follows:
     (a) Remove the nut (344).
     (b) Remove and discard the lockwasher (343).
     (c) Remove the washer (342)
     (d) Adjust the setscrew (345) until the stop (347) installed on the bellcrank (333) touches the door structure.
     (e) Apply Cetyl Alcohol base Lubricant-Fasteners Water base - (Material No.03RBB1) on the threads of the setscrew (346).
     (f) Install the washer (342) and the new AIPC 52-11-11-14-340 LOCKWASHER (343).
     (g) Install the nut (344) and tighten it.
     (h) Safety the nut (344) with the lockwasher (343).
   (28) Do a check of the rigging of the bellcrank (346) on the compensation mechanism with the 98DNSA20206060 RIGGING PIN. The door is in the up position.
   (29) Remove the 98D52103006000 PIN - RIGGING, DOOR ADJUST from the fitting (306) and the bellcrank (333).
Subtask 52-11-21-420-058-A
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
K. Installation of the Compensation Mechanism
F Torsion Bar - Compensation Mechanism
F Compensation Mechanism Adjustment
   (1) Make sure that the door is in the open position.
   (2) Install the spacer (538), the crank (539) and the spacer (541) on the sleeve (537).
   (3) Make sure that the grooves are aligned when you install the crank (539) on the sleeve (537).
   (4) Put the sleeve (537) in position and push it to the outer side of the door.
   (5) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the bearing assembly (542) that touches the door structure.
   (6) Install the bearing assembly (542), the bolts (503) and the nuts (513) and tighten them.
   (7) Install the sleeve (537) on the bearing assembly (542) and put the spacer (543) between the sleeve (537) and the bearing assembly (542).
   (8) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the bearing assembly (535) that touches the door structure.
   (9) Install the bearing assembly (535), the bolts (502) and the nuts (501) and tighten them.
   (10) Install the washer (544).
   (11) Install the STA-LOK nut (545) (Ref. AMM TASK 20-22-00-400-001).
   (12) TORQUE the STA-LOK nut (545) to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in ) T.
   (13) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the bearing assembly (523) that touches the door structure.
   (14) Install the bearing assembly (523), the bolts (524) and the nuts (522) and tighten them.
   (15) Install the washer (519) and the spacer (520) on the torsion tube (518).
   (16) Install the torsion tube (518) in the bearing (523).
   (17) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the bearing assembly (517) that touches the door structure.
   (18) Install the bearing assembly (517), the bolts (547) and the nuts (546) and tighten them.
   (19) Install the spacer (526), the bellcrank (527) and the washer (529) on the torsion tube (518).
   (20) Make sure that the grooves are aligned when you install the bellcrank (527) on the torsion tube (518).
   (21) Install the STA-LOK nut (530) on the torsion tube (518) (Ref. AMM TASK 20-22-00-400-001).
   (22) TORQUE the STA-LOK nut (530) to between 0.4 and 0.3 m.daN (35.40 and 26.55 lbf.in ) T.
   (23) Install the torsion bar (514) to get an angle of 90 degrees between the bellcranks (527) and (539).
   (24) Install the washers (516) and (534) and the retaining rings (515) and (533).
   (25) Install the half bushings (531) and the clamps (532).
   (26) Make sure that clearance J14 between the half bushings (531) and the STA-LOK nut (530) is 1 +0 mm or +3 mm (0.04 +0.00 in. or +0.12 in.).
   (27) Connect the rod (528) as follows:
     (a) Install the 98DNSA20206060 RIGGING PIN in the bellcrank (527) (door in the up position).
     (b) Cut and discard the lockwire from the nuts (560).
     (c) Loosen the nuts (560) and release the lockwashers (561).
     (d) Turn the barrel of the rod (528) until you can connect it.
     (e) Install the bushes (551) and (552) with Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) , the washer (553) and the bolt (554).
     (f) Install the washer (550) and the nut (548).
     (g) TORQUE the nut (548) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (h) Install the new AIPC 52-11-11-13-010 COTTER PIN (549) or the new AIPC 52-11-81-14-010 COTTER PIN (549).
     (i) If you must install a new bolt (554), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
     (j) Remove the 98DNSA20206060 RIGGING PIN.
   (28) Connect the link (510) as follows:
     (a) Install the yoke (540).
     (b) Install the washer (511), bolt (512), washer (504) and nut (505).
     (c) Tighten the nut (505).
     (d) Install the new AIPC 52-11-11-13-170 COTTER PIN (506) or the new AIPC 52-11-81-14-170 COTTER PIN (506).
     (e) If you must install a new bolt (521), drill a hole with a diameter of 1.8 mm (0.07 in.) for the cotter pin installation.
   (29) Preload the compensation mechanism as follows:
     (a) Turn the screw (565) until dimension L3 is 30 +10 mm or -0 mm (1.18 +0.39 in. or +0.00 in.).
   (30) Make sure that you can install the 98DNSA20206060 RIGGING PIN in the bellcrank (527).
   (31) If you cannot install it, adjust the length of the rod (528) again.
   (32) Remove the unwanted sealant from the bearing assemblies (542), (535), (523) and (517) with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
Subtask 52-11-21-420-059-A
WARNING: USE PROTECTIVE GOGGLES WHEN YOU REMOVE OR INSTALL A COTTER PIN. EACH TIME YOU REMOVE A COTTER PIN DURING THE TASK, DISCARD IT IMMEDIATELY. A LOOSE COTTER PIN CAN CUT YOU OR MAKE YOU BLIND.
L. Installation of the Upper and Lower Connection Links
F Upper and Lower Connection Links
F Upper and Lower Lifting Levers-Adjustment
   (1) Make sure that the door is closed and locked.
   (2) Connect the upper connection link (461) as follows:
     (a) Install the washer (464) on the bush (463) with Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) .
     (b) Install the bushes (463) and (460) with Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) in the door structure.
     (c) Install the adjustable washer (462) on the bolt (459).
     (d) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the surface of the bolt (459) that touches the bushes (460) and (463).
     (e) Put the upper connection link (461) in position and install the bolt (459).
     (f) Install the bushing (465) with Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) , the washer (466) and the nut (467).
     (g) TORQUE the nut (467) to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in ) T.
     (h) Make sure that clearance J17 is 0 +0 mm or +0.1 mm (0.00 +0.00 in. or +0.00 in.).
     (i) If clearance J17 is not in the tolerance, adjust the thickness of the adjustable washer (462).
     (j) Install the new AIPC 52-11-11-12-060 COTTER PIN (450) or the new AIPC 52-11-81-13-060 COTTER PIN (450).
     (k) If you must install a new bolt (459), drill a hole with a diameter of 2 mm (0.08 in.) for the cotter pin installation.
   (3) Connect the lower connection link (423) as follows:
     (a) Install the washer (428) on the bush (427) with Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) .
     (b) Install the bushes (427) and (436) on the door structure with Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) .
     (c) Install the adjustable washer (426) on the bolt (419).
     (d) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) on the surface of the bolt (419) that touches the bushes (427) and (436).
     (e) Put the lower connection link (423) in position and install the bolt (419).
     (f) Make sure that clearance J17 is 0 +0 mm or +0.1 mm (0.00 +0.00 in. or +0.00 in.).
     (g) If clearance J17 is not in the tolerance, adjust the thickness of the adjustable washer (426).
     (h) Install the bushing (429) with Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) , the washer (430) and the nut (402).
     (i) TORQUE the nut (402) to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in ) T.
     (j) Install the new AIPC 52-11-11-12-060 COTTER PIN (401) or the new AIPC 52-11-81-13-060 COTTER PIN (401).
     (k) If you must install a new bolt (419), drill a hole with a diameter of 2 mm (0.08 in.) for the cotter pin installation.
   (4) Connect the rod (435) as follows:
     (a) Install the bushes (433) and (434) with Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) .
     (b) Install the washer (432) and the bolt (431).
     (c) Install the washer (421) and the nut (422).
     (d) TORQUE the nut (422) to between 0.7 and 0.6 m.daN (61.95 and 53.10 lbf.in ) T.
     (e) Install the new AIPC 52-11-11-14-010 COTTER PIN (420).
     (f) If you must install a new bolt (431), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (5) Connect the rod (417) as follows:
     (a) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the bushes (413) and (414).
     (b) Install the bushes (413) and (414).
     (c) Install the washer (412) and the bolt (411).
     (d) Install the washer (437) and the nut (415).
     (e) TORQUE the nut (415) to between 0.35 and 0.3 m.daN (30.97 and 26.55 lbf.in ) T.
     (f) Install the new AIPC 52-11-11-13-010 COTTER PIN (416) or the new AIPC 52-11-81-14-010 COTTER PIN (416).
     (g) If you must install a new bolt (411), drill a hole with a diameter of 1.9 mm (0.07 in.) for the cotter pin installation.
   (6) Connect the upper and lower connection links (423) and (461) to the support arm (410):
     (a) Install the washers (404) and (452), bolts (403) and (451), sets of washers (409) and (458), washers (418) and (455) and nuts (405) and (456).
     (b) TORQUE the nuts (405) and (456) to between 1.35 and 1.2 m.daN (119.47 and 106.19 lbf.in ) T.
     (c) Install the new AIPC 52-11-01-04-150 COTTER PIN (401) or the new AIPC 52-11-81-02-150 COTTER PIN (401) and the new AIPC 52-11-01-04-150 COTTER PIN (450) or the new AIPC 52-11-81-02-150 COTTER PIN (450).
     (d) Put the bonding leads (425) and (468) in position and install the bolt (429) and (469).
     (e) Install the bonding leads (407) and (453) and the nuts (408) and (454) and tighten them:
       1 Do an electrical bonding when you install the bonding leads (407) and (453) (Ref. AMM TASK 20-28-00-912-802).
   (7) Open the door.
   (8) With the door in the up position, rig the bellcrank (472) with the 98DNSA20206060 RIGGING PIN.
   (9) If the rigging is not correct, adjust the length of the rod (417) as follows:
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
     (a) Cut and discard the lockwire from the nuts (470).
     (b) Loosen the nuts (470) and release the lockwashers (471).
     (c) Turn the barrel of the rod (417) until you can connect it.
     (d) Tighten the nuts (470) and make sure that the lockwashers (471) are in the correct position.
     (e) Remove the 98DNSA20206060 RIGGING PIN.
   (10) Install the window (Ref. AMM TASK 56-31-11-400-002).
   (11) Install the plate assembly:
F Plate Assembly
     (a) Apply Polysulfide Sealant-Low Adhesion Brushable - (Material No.06AEA1) on the surface of the plate assembly (181) that touches the door structure.
     (b) Put the plate assembly (181) in position.
     (c) Apply Polysulfide Sealant-General Purpose Fillet - (Material No.06AAB1) on the housing of the screws (182) and (184).
     (d) Install the washers (183) and the screws (182) and (184).
     (e) Tighten the screws (182) and (184).
     (f) Remove the unwanted sealant with Non Aqueous Cleaner-General - - (Material No.08BAA9) and the Textile-Lint free Cotton - (Material No.14SBA1) .
Subtask 52-11-21-420-060-A
M. Adjustment of the Tension of the Compensation Mechanism
F Release of the Compensation Mechanism
NOTE: It is necessary to adjust the tension of the torsion bar only if these components were removed:
  • The outer control handle
  • The gearbox
  • The upper and lower connection links
  • The compensation mechanism
  • The reducer shaft.
   (1) Measure the load on the inner control handle with the DYNAMOMETER 20 DAN (45 LBF) - PULL.
   (2) Adjust the tension of the torsion bar to get a load less than or equal to 18 daN (40.47 lbf) to open the door with the inner control handle.
   (3) To do this, turn the screw (1).
WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.
   (4) Safety the screw (1) with the 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
5. Close-up
Subtask 52-11-21-820-052-A
A. Adjustment
   (1) Do the adjustment of the door locking mechanism (Ref. AMM TASK 52-11-21-820-001).
Subtask 52-11-21-640-050-A
B. Lubrication
   (1) Lubricate the ends of the girt bar with Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) .
   (2) Lubricate the contact surfaces of the girt bar and the girt bar fittings with Silicone base Grease-General Purpose - - (Material No.03JBA1) .
Subtask 52-11-21-916-050-A
C. Protective Treatment
   (1) Apply Primer Polyurethane Paint_- Corrosion Inhibiting Structure (Material No.04EAC2) on the ends of the screw threads and heads.
   (2) Apply one more layer of Top Coat Polyurethane_- Grey Internal Structure (Material No.04JME4) .
   (3) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the screws of the door locking mechanism.
   (4) Apply a layer of Corrosion Preventive Compound-Heavy Duty Soft Film - (Material No.12ACC1) on the metal parts which are not painted.
   (5) Apply a layer of Corrosion Preventive Compound-Water Displacing Oily Film System (Material No.12ABE2) on all the parts installed.
Subtask 52-11-21-410-060-A ** ON A/C NOT FOR ALL
D. Installation of Components
   (1) Remove the 98D52103501000 BALLAST WEIGHT - PASSENGER CREW DOOR (Ref. AMM TASK 52-10-00-080-001).
   (2) Install the door insulation.
   (3) Install the escape slide:
     (a) For the left door:
     (b) For the right door:
   (4) Install the door lining panels (Ref. AMM TASK 25-23-46-400-001):
     (a) For the left forward passenger/crew door: 831, 831AZ, 831BZ, 831CZ, 831DZ and 831EZ
     (b) For the right forward passenger/crew door: 841, 841AZ, 841BZ, 841CZ, 841DZ and 841EZ.
   (5) Install the lining flap (Ref. AMM TASK 52-11-31-400-001).
Subtask 52-11-21-410-060-B ** ON A/C NOT FOR ALL
D. Installation of Components
   (1) Remove the 98D52103501000 BALLAST WEIGHT - PASSENGER CREW DOOR (Ref. AMM TASK 52-10-00-080-001).
   (2) Install the door insulation.
   (3) Install the door lining panels (Ref. AMM TASK 25-23-46-400-001).
     (a) For the left forward passenger/crew door: 831, 831AZ, 831BZ, 831CZ, 831DZ and 831EZ
     (b) For the right forward passenger/crew door: 841, 841AZ, 841BZ, 841CZ, 841DZ and 841EZ.
   (4) Install the escape slide:
     (a) For the left door:
     (b) For the right door:
   (5) Install the lining flap (Ref. AMM TASK 52-11-31-400-001).
Subtask 52-11-21-865-059-A
E. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):
PANELDESIGNATIONFINLOCATION
** ON A/C ALL
121VUEIS/SLIDES/ARM AND WARN/FLT15WNP11
121VUEIS/SLIDES/ARM AND WARN/GND13WNP10
121VUEIS/SDAC1 AND 2/DOOR/DET/PAX48WVP05
Subtask 52-11-21-410-061-A
F. Close Access
   (1) Obey the special precautions after the work on the passenger/crew door (Ref. AMM TASK 52-10-00-860-002).
   (2) Remove the ground support and maintenance equipment, the special and standard tools and all other items.
   (3) Make sure that the work area is clean and clear of tools and other items.
   (4) Close passenger/crew door 831 or 841 (Ref. AMM TASK 52-10-00-410-001).
   (5) Remove the access platform(s).
[Rev.10 from 2021] 2026.04.02 06:27:23 UTC
"WTRUIB" 2025