Installation of the Overwing Emergency-Exit Door

TASK 52-22-61-400-802-A
Installation of the Overwing Emergency-Exit Door

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

WARNING: YOU MUST MAKE SURE THAT YOU CAN HOLD THE COMPONENT BEFORE YOU REMOVE/INSTALL IT. THE COMPONENT IS HEAVY. IF IT FALLS, IT CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

NOTE: Two persons are necessary for this procedure.

NOTE: The weight of this equipment is approximately 25.5 kg (56.2179 lb).

ZONE: 833
ZONE: 834
ZONE: 843
ZONE: 844

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 4M (13 FT)-ADJUSTABLE
No specific	1	CRANE 50KG (110 LB)
No specific	1	SCRAPER - PLASTIC
No specific	Torque wrench: range to between 10.34 and 8.46 m.N (91.50 and 74.87 lbf.in )
98A52008509000	1	SLING-UNIVERSAL,DOORS
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION
98L12003001000	AR	HARNESS,SAFETY

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03GBC1)	Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. -
(Material No.04SAB2)	Varnish Polyurethane-- Marking Structure
(Material No.06AAB1)	Polysulfide Sealant-General Purpose Fillet -
(Material No.06AAC1)	Polysulfide Sealant-General Purpose Interfay -
(Material No.06LCG9)	Non Hardening Jointing Putty-Medium Temp. Area - -
(Material No.08BBD1)	Non Aqueous Cleaner-- Isopropyl Alcohol -
(Material No.14SBA1)	Textile-Lint free Cotton -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
833	EMERGENCY EXITS
834	EMERGENCY EXITS
843	EMERGENCY EXITS
844	EMERGENCY EXITS
833, 834, 843, 844

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
10	COTTER PINS	AIPC 52-21-84-30-590

E. Referenced Information

REFERENCE	DESIGNATION
TASK 11-00-00-400-022-A	Installation of the Hoisting-Point Cover Patches
TASK 12-00-00-481-002-A	Installation of the Wingrip
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 24-41-00-861-002-A	Energize the Aircraft Electrical Circuits from the External Power
TASK 24-41-00-861-002-A-01	Energize the Aircraft Electrical Circuits from the APU
TASK 24-41-00-861-002-A-02	Energize the Aircraft Electrical Circuits from Engine 1(2)
TASK 24-41-00-862-002-A	De-energize the Aircraft Electrical Circuits Supplied from the External Power
TASK 24-41-00-862-002-A-01	De-energize the Aircraft Electrical Circuits Supplied from the APU
TASK 24-41-00-862-002-A-02	De-energize the Aircraft Electrical Circuits Supplied from the Engine 1(2)
TASK 25-23-47-000-805-A	Removal of the Door Frame Lining from the Overwing Emergency Exit
TASK 25-23-47-400-805-A	Installation of the Door Frame Lining on the Overwing Emergency Exit
TASK 25-23-48-000-001-A	Removal of the Cove Light Panel
TASK 25-23-48-400-001-A	Installation of the Cove Light Panel
TASK 25-24-41-000-001-A	Removal of the Overhead Stowage Compartments (OHSC)
TASK 25-24-41-400-001-A	Installation of the Overhead Stowage Compartments (OHSC)
TASK 25-62-00-081-001-A	Special Precautions after Work on the Offwing Escape-Slide Systems
TASK 25-80-00-000-001-A	Removal of the Insulation Blankets
TASK 25-80-00-400-001-A	Installation of the Insulation Blankets
TASK 27-00-00-480-002-A	Installation of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
TASK 52-22-00-410-802-A	Closing of the Overwing Emergency-Exit Door from the Passenger Compartment
TASK 52-22-00-820-802-A	Adjustment of the Overwing Emergency-Exit Door
TASK 52-22-00-820-803-A	Adjustment of the Locking Hooks
TASK 52-22-61-000-802-A	Removal of the Overwing Emergency-Exit Door
TASK 52-71-00-820-805-A	Adjustment of the Proximity Switches of the Overwing Emergency-Exit Door
Overwing Emergency-Exit Door - Lift Arms and Electrical Connections
Overwing Emergency-Exit Door - Hinges
Hoisting Sling of the Overwing Emergency-Exit Door

3. Job Set-up
Subtask 52-22-61-860-054-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Put on a safety harness:

WARNING: YOU MUST PUT ON AND ATTACH A SAFETY HARNESS BEFORE YOU START WORK:

ON THE THS OR IN THE REAR FUSELAGE
ON TOP OF THE WINGS OR PYLONS.

WITHOUT A SAFETY HARNESS, YOU CAN FALL. THIS CAN KILL YOU OR CAUSE YOU INJURY.

(a) If you work on the wings, make sure that the individual pad system is installed (Ref. AMM TASK 12-00-00-481-002).
(b) Put on and attach the HARNESS, SAFETY before you start work in the work area.
(2) Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is installed on the flap/slat control lever (Ref. AMM TASK 27-00-00-480-002).
(3) Make sure that the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE is in position near applicable overwing emergency-exit door 833 ( 843) or 834 ( 844).
(4) Make sure that the aircraft electrical circuits are energized (Ref. AMM TASK 24-41-00-861-002).
(5) In the cockpit, make sure that the WARNING NOTICE(S) is(are) in position to tell persons not to operate the flight controls.
(6) On the overhead panel, on the SIGNS section of the control panel 25VU, make sure that:

The EMER EXIT LT switch is in the OFF position.
The NO PED switch is in the OFF position.

(7) Put the WARNING NOTICE(S) in position to tell persons not to operate these switches.
(8) On Flight Attendant Panel (FAP) 120RH, make sure that the EMER button and its light are off.
(9) Make sure that the applicable cove light panel is removed (Ref. AMM TASK 25-23-48-000-001).
(10) Make sure that the adjacent door frame linings are removed (Ref. AMM TASK 25-23-47-000-805).
(11) Make sure that the adjacent overhead stowage compartment are removed (Ref. AMM TASK 25-24-41-000-001).
(12) Make sure that the applicable insulation is removed (Ref. AMM TASK 25-80-00-000-001).
(13) Make sure that the 98A52008509000 SLING-UNIVERSAL,DOORS (104) is installed (Ref. AMM TASK 52-22-61-000-802).

Subtask 52-22-61-865-054-A ** ON A/C NOT FOR ALL

B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/SEC1/NORM/SPLY	21CE1	B03
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B01
49VU	LIGHTING/EMER LT/CABIN	2WL	H04
49VU	LIGHTING/EMER LT/CABIN	1WL	H03
105VU	FLT CTL/SEC1/STBY SPLY	22CE	B01
121VU	EIS/SLIDES/ARM AND WARN/FLT	15WN	P11
121VU	EIS/SLIDES/ARM AND WARN/GND	13WN	P10
121VU	EIS/SDAC1 AND 2/DOOR/DET/PAX	48WV	P05
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21
121VU	FLIGHT CONTROLS/SEC3/SPLY	21CE3	Q19
121VU	FLIGHT CONTROLS/SEC2/SPLY	21CE2	Q18
121VU	FLIGHT CONTROLS/SLT/CTL/SYS2	7CV	R21
122VU	FLIGHT LOCK OWD	40WN	U16
122VU	LIGHTING/CABIN/EMER/LT	3WL	V07

Subtask 52-22-61-910-051-A ** ON A/C NOT FOR ALL

C. Preparation for Installation

Overwing Emergency-Exit Door - Lift Arms and Electrical Connections ** ON A/C NOT FOR ALL

Overwing Emergency-Exit Door - Hinges ** ON A/C NOT FOR ALL

(1) Do an inspection of the component interfaces and the adjacent area.
(2) Make sure that the parts retained from the removed component are clean and in the correct condition.
(3) Clean the component interface and/or the adjacent area with the Textile-Lint free Cotton - (Material No.14SBA1) and Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) .
(4) Apply a thin layer of Synthetic Oil base Grease-General Purpose Lithium Thickened Low Temp. - (Material No.03GBC1) on:

The hinge pins (32)
The plain bushings (2)
The shaft of the bolts (1).

(5) Apply a thin layer of Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) on the threads of the bolts (1).
(6) Use the SCRAPER - PLASTIC to remove the remaining sealant from:

The hinges (37) and (39)
The lateral hinges of the overwing emergency-exit door (31)
The fuselage lateral hinges.

(7) Apply a thin layer of Polysulfide Sealant-General Purpose Interfay - (Material No.06AAC1) to the threads of the screws (33), (34), (35) and (36) and to the mating surfaces of the hinges (37) and (39).

4. Procedure
Subtask 52-22-61-420-051-A ** ON A/C NOT FOR ALL

A. Installation of the Overwing Emergency-Exit Door

WARNING: MAKE SURE THAT THE TRAVEL RANGE OF THE OVERWING EMERGENCY DOOR IS CLEAR BEFORE YOU PUT IT ON THE FUSELAGE FRAME. IF THE OVERWING EMERGENCY DOOR MOVES, IT CAN CAUSE INJURY OR DEATH TO PERSONNEL AND DAMAGE TO THE EQUIPMENT.

WARNING: MAKE SURE THAT ONE PERSON HOLDS THE OVERWING EMERGENCY-EXIT DOOR MANUALLY UNTIL THE HINGES ARE ATTACHED. UNWANTED MOVEMENT OF THE OVERWING EMERGENCY-EXIT DOOR CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO THE OVERWING EMERGENCY-EXIT DOOR AND/OR THE FUSELAGE.

(1) On the fuselage frame, put the overwing emergency-exit door (31) in position:

NOTE: Two persons are necessary for this part of the procedure. One person holds the overwing emergency-exit door (31) and the other installs the hinge pins (32).

(a) Use the 98A52008509000 SLING-UNIVERSAL,DOORS (104) and the CRANE 50KG (110 LB) to put the overwing emergency-exit door (31) in position on the fuselage frame.
1 Make sure that the bores of the lateral hinges of the overwing emergency-exit door (31) and the fuselage lateral hinges are correctly aligned.
2 Do not fully close the overwing emergency-exit door (31).

NOTE: The opening of the overwing emergency-exit door (31) must have a bottom clearance of a minimum of 250 mm (9.84 in.).

(b) Hold the overwing emergency-exit door (31) in position.
(2) Install the forward hinge pin (32) and then the aft hinge pin (32) to connect the lateral hinges of the overwing emergency-exit door (31) with the fuselage lateral hinges.
(3) Install the center hinge (40):
(a) Remove and discard the TAPE - ADHESIVES from the ends of the pin (38).
(b) Carefully put and hold the center hinge (40) in position on the overwing emergency-exit door (31).

CAUTION: MAKE SURE THAT YOU INSTALL EACH OF THE SCREWS IN ITS CORRECT POSITION. THE SCREWS HAVE DIFFERENT LENGTHS. IF YOU DO NOT INSTALL EACH OF THE SCREWS IN ITS CORRECT POSITION, YOU CAN CAUSE DAMAGE.

(c) Install the screws (33), (34), (35) and (36).
(d) TORQUE the screws (33), (34), (35) and (36) to between 10.34 and 8.46 m.N (91.50 and 74.87 lbf.in )

.
(e) Make sure that for applicable overwing emergency-exit door 833 ( 843) or 834 ( 844), the lateral clearances are correct (Ref. AMM TASK 52-22-00-820-802).
(f) Apply Polysulfide Sealant-General Purpose Fillet - (Material No.06AAB1) to the upper and lower edges of all the hinges and to the protruding threads of the screws (33), (34), (35) and (36).
(g) Fill the spaces between all the hinges with Polysulfide Sealant-General Purpose Fillet - (Material No.06AAB1) .
(4) Lift the overwing emergency-exit door (31):

WARNING: WHEN YOU LIFT THE OVERWING EMERGENCY-EXIT DOOR:

DO NOT MOVE IT TOO QUICKLY, AND
MAKE SURE THAT ONE PERSON HOLDS IT MANUALLY UNTIL IT IS AT AN ANGLE OF APPROXIMATELY 90 DEGREES.

IF YOU DO NOT OBEY THESE INSTRUCTIONS, THE OVERWING EMERGENCY-EXIT DOOR CAN OPEN SUDDENLY. THIS CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO THE HINGE STRUCTURE OF THE OVERWING EMERGENCY-EXIT DOOR.

CAUTION: MAKE SURE THAT THE DISTANCE BETWEEN THE OVERWING EMERGENCY-EXIT DOOR AND THE HOISTING DEVICE IS SUFFICIENT TO PREVENT DAMAGE TO THE OVERWING EMERGENCY-EXIT DOOR WHEN IT IS FULLY OPEN.

CAUTION: DO NOT LIFT THE OVERWING EMERGENCY-EXIT DOOR AT AN ANGLE OF MORE THAN 112 DEGREES. IF YOU DO, DAMAGE TO THE HINGE STRUCTURE OF THE OVERWING EMERGENCY-EXIT DOOR CAN OCCUR.

(a) Slowly and carefully lift the overwing emergency-exit door (31) with your hands to approximately 90 degrees.
(5) Connect the lift arms (11):
(a) Remove and discard the TIE WRAP(S) from the lift arms (11).
(b) Put the washers (7) and the lift arms (11) in their installation position on the fittings (6).
(c) Install the plain bushings (2), the bolts (1), the washers (8) and the nuts (9).
(d) Tighten the nuts (9).

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.

(e) Safety the nuts (9) with the new AIPC 52-21-84-30-590 COTTER PINS (10).
(f) Apply Varnish Polyurethane-- Marking Structure (Material No.04SAB2) to the nuts (9) and the heads of the bolts (1).
(6) Connect the bonding straps (5):
(a) Cut and discard the TIE WRAP(S) (13).
(b) Put the bonding straps (5) in position and install the washers (4) and the bolts (3) (Ref. AMM TASK 20-28-00-912-802).
(c) Tighten the bolts (3).
(d) Apply Varnish Polyurethane-- Marking Structure (Material No.04SAB2) to the heads of the bolts (3).
(7) Connect the electrical connector (12):
(a) Cut and discard the TIE WRAP(S) (13).
(b) Remove the CAP-BLANKING from each electrical connector and receptacle.
(c) Connect the electrical connector (12).
(d) Safety the cable (14) with the new TIE WRAP(S) (13).
(e) Install the clamp (15), the washer (16) and the screw (17).
(f) Tighten the screw (17).

Subtask 52-22-61-410-051-A ** ON A/C NOT FOR ALL

B. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Remove the 98A52008509000 SLING-UNIVERSAL,DOORS (104):

Hoisting Sling of the Overwing Emergency-Exit Door ** ON A/C NOT FOR ALL

(a) Remove the ring bolts (105) together with the protection washers (106) from the hoisting points (103).
(b) Remove the 98A52008509000 SLING-UNIVERSAL,DOORS (104) from the CRANE 50KG (110 LB).
(c) Install the plugs (102) into the hoisting points (103).
(d) Make sure that the plugs (102) are flush with the outer door skin.
(e) Install the new self-adhesive disks (101) on the hoisting points (103) (Ref. AMM TASK 11-00-00-400-022).
(f) Remove the 98A52008509000 SLING-UNIVERSAL,DOORS (104) and the CRANE 50KG (110 LB).
(3) Remove the individual pad system (Ref. AMM TASK 12-00-00-481-002).
(4) Remove the access platform(s).
(5) Close applicable overwing emergency-exit door 833( 843) or 834( 844) (Ref. AMM TASK 52-22-00-410-802).
(6) Do a check of the lift arms (11) and make sure that the nuts (9) are safetied with the cotter pins (10).
(7) Install the removed insulation blankets (Ref. AMM TASK 25-80-00-400-001).
(8) Install the removed overhead stowage compartment(s) (Ref. AMM TASK 25-24-41-400-001).
(9) Install the removed door frame lining(s) (Ref. AMM TASK 25-23-47-400-805).
(10) Install the removed cove light panel(s) (Ref. AMM TASK 25-23-48-400-001).

Subtask 52-22-61-865-055-A ** ON A/C NOT FOR ALL

C. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	FLIGHT CONTROLS/SEC1/NORM/SPLY	21CE1	B03
49VU	FLIGHT CONTROLS/FLP/CTL AND MONG/SYS1	6CV	B02
49VU	FLIGHT CONTROLS/SLT/CTL AND MONG/SYS1	5CV	B01
49VU	LIGHTING/EMER LT/CABIN	2WL	H04
49VU	LIGHTING/EMER LT/CABIN	1WL	H03
105VU	FLT CTL/SEC1/STBY SPLY	22CE	B01
121VU	EIS/SLIDES/ARM AND WARN/FLT	15WN	P11
121VU	EIS/SLIDES/ARM AND WARN/GND	13WN	P10
121VU	EIS/SDAC1 AND 2/DOOR/DET/PAX	48WV	P05
121VU	FLIGHT CONTROLS/FLP/CTL AND/MONG/SYS2	8CV	Q21
121VU	FLIGHT CONTROLS/SEC3/SPLY	21CE3	Q19
121VU	FLIGHT CONTROLS/SEC2/SPLY	21CE2	Q18
121VU	FLIGHT CONTROLS/SLT/CTL/SYS2	7CV	R21
122VU	FLIGHT LOCK OWD	40WN	U16
122VU	LIGHTING/CABIN/EMER/LT	3WL	V07

Subtask 52-22-61-710-051-A ** ON A/C NOT FOR ALL

D. Check of the Overwing Emergency-Exit Door
(1) Open applicable overwing emergency-exit door 833 ( 843) or 834 ( 844) (Ref. AMM TASK 52-22-00-410-802) and make sure that it moves smoothly and easily.
(2) Make sure that applicable overwing emergency-exit door 833 ( 843) or 834 ( 844) is correctly adjusted (Ref. AMM TASK 52-22-00-820-802).
(3) Close applicable overwing emergency-exit door 833 ( 843) or 834 ( 844) (Ref. AMM TASK 52-22-00-410-802).
(4) Make sure that the locking hooks are correctly adjusted (Ref. AMM TASK 52-22-00-820-803).
(5) Make sure that the proximity switches are correctly adjusted (Ref. AMM TASK 52-71-00-820-805).

5. Close-up
Subtask 52-22-61-860-055-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Remove the WARNING NOTICE(S).
(2) Do the special precautions after you work on the offwing escape-slide system (Ref. AMM TASK 25-62-00-081-001).
(3) De-energize the aircraft electrical circuits
(Ref. AMM TASK 24-41-00-862-002).

[Rev.10 from 2021] 2026.04.02 06:27:45 UTC