Chapter 52 DOORS 52-Title Page 1 January 23, 2012
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LIST OF EFFECTIVE PAGES Chapter Section Page No. Date 52 52-Title 1 January 23, 2012 2 January 23, 2012 52-LOEP 1 January 23, 2012 2 January 23, 2012 52-TOC 1 January 23, 2012 2 January 23, 2012 52-10 1 2 3 4 52-15 1 2 3 4 5 6 7 8 52-17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 52-LOEP Page 1 January 23, 2012
LIST OF EFFECTIVE PAGES Chapter Section Page No. Date 52 52-17 19 20 52-30 1 2 3 4 52-35 1 2 3 4 5 6 7 8 52-37 1 2 3 4 5 6 7 8 9 52-LOEP Page 2 January 23, 2012
TABLE OF CONTENTS Chapter Section Title 52 Doors 52-Title Title Page 52 -LOEP List of Effective Pages 52 -TOC Table of Contents 52-10 Aluminum Forward Door (2C1) 52-10-10 General 52-10-20 Forward Door Hinges 52-10-30 Forward Door Latch 52-10-31 Forward Door Latch Adjustments 52-10-40 Door Locks 52-15 Composite Forward Doors (2C1 & 2C2) 52-15-00 General 52-15-10 Forward Door Removal and Installation (2C1 & 2C2) 52-17 Composite Forward Doors (2C3 & 2C4) 52-17-00 General 51-17-10 Door Removal & Installation 52-17-20 Interior Handle 51-17-30 Exterior Handle 52-17-40 Door Latch Assembly 51-17-50 Exterior Handle Cable Assembly Replacement 51-17-55 Interior Handle Cable Replacement 51-17-60 Interior Handle Cable Adjustment 52-17-65 Exterior Handle Cable Adjustment 51-17-70 Gas Shock Replacement 52-17-75 Hinge Replacement 51-17-80 Striker Bolt Replacement 51-17-85 Door Seal Replacement 52-30 Aluminum Aft Door (2C1) 52-30-00 General 52-30-10 Aft Door Hinges 52-30-20 Aft Door Latch 52-30-21 Aft Door Latch Adjustments 52-35 Composite Aft Door (2C1 & 2C2) 52-35-00 General 52-35-10 Removal and Installation 52-37 Composite Aft Doors (2C3 & 2C4) 52-37-00 General 52-37-10 Door Removal & Installation 52-37-20 Interior Handle 52-37-30 Exterior Handle 52-TOC Page 1 January 23, 2012
TABLE OF CONTENTS Chapter Section Title 52 52-37-40 Door Latch Assembly 52-37-50 Exterior Handle Cable Assembly Replacement 52-37-55 Interior Handle Cable 52-37-60 Interior Handle Cable Adjustment 52-37-65 Exterior Handle Adjustment 52-37-70 Gas Shock Replacement 52-37-75 Hinge Replacement 52-37-80 Striker Bolt Replacement 52-37-85 Door Seal Replacement 52-TOC Page 2 January 23, 2012
52 DOORS 52-10 ALUMINUM FORWARD DOORS (2C1) 52-10-10 General There are four doors on the aircraft. There are two forward doors for a pilot and a second person, and two aft doors for the loading of cargo and passengers. All four doors are constructed of frame with a formed inner aluminum panel exterior aluminum skin, as well as moulded plastic interior trim. All doors have a weather seal running completely around the circumference. All doors swing through 180 of travel, and the aft doors may be fully opened with the flaps in any position. Both forward doors are hinged at the forward side at Arm 0 with two simple hinges. A latch mechanism allows the door to be opened from either inside or outside, but may be manually locked from the inside only. A keyed lock in the Port latch mechanism allows the door to be locked from the outside. If the keyed lock is engaged while the door is open, the door may be closed without first unlocking it. Door Removal and Installation Step 1. Support the door in such a manner that further disassembly will not damage the door. Step 2. Remove the cotter pins in the two hinge pins and withdraw the hinge pins. Door is now free. To install forward door reverse above steps. 52-10-20 Forward Door Hinges The forward door hinge segments are fully interchangeable between left and right and upper and lower. The hinges are not interchangeable between the forward door and the aft door. Hinge Removal and Installation Step 1. Remove door (Ref : Chapter 52-10-10). Step 2. Remove the four screws which hold the hinge to the fuselage or door. To install hinge reverse above steps. 52-10 Page 1
52-10-30 Forward Door Latch Each of the forward door latches serves as a means to secure the door in the closed position. See Figure 52-10-01. 52-10-31 Forward Door Latch Adjustments When the door is closed and latched, the latch pin must penetrate the latch pin socket in the door frame by a minimum of 0.250. Step 1. Remove the inside cover (Ref: Figure 52-10-01) to gain access to the latch assembly. Step 2. Loosen off the jamb nut on the aft end of the latch pin. Step 3. Turn the barrel nut the required direction then tighten the jamb nut. Step 4. Close and latch the door to ensure correct depth in door frame. 52-10-40 Door Locks To secure the door from inside, or to lock the door, the lock knob is rotated which prevents the latch mechanism from moving. 52-10 Page 2
PORT DOOR LATCH LOOKING INBOARD PORT DOOR LATCH LOOKING OUTBOARD STBD DOOR LATCH LOOKING OUTBOARD Figure 52-10-01: Aluminium Forward Door Latch (2C1) 52-10 Page 3
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52-15 COMPOSITE FORWARD DOORS (2C1 AND 2C2) 52-15-00 General There are four doors on the aircraft which hinge open to the forward Position. The two forward doors provide access to the two forward seats of the aircraft for the pilot and another person. The forward port door is described; the forward starboard door is similar. Differences between the doors will be indicated. Door Description Refer to Figure 52-15-01 Features of each forward door are as follows: - structured fiberglass construction for strength and durability. - large "L-shaped" bubble windows. - extra shoulder room due to bubble windows. - arm rests on the door. - interiors which feature durable trim panels. - doors that may be latched and locked - an external keyed lock on the door of the port side. - labels with operating instructions. - maintenance access panels - a rubber perimeter seal. - door pull handles integrated into the arm rests. - document pockets - stainless steel door hinges - some interchangeable door hinges - drain holes on the lower parts of the door - a retainer for door fully open 52-15 Page 1
11 12 13 9 14 10 EXIT OPEN 7 1 8 2 15 6 4 3 7 LEGEND 1. Bubble WIndow 8. Door Knob 2. Label 9. Door Lock Button 3. Door Knob 10. Label 4. Key Lock 11. Perimeter Seal 5. Fiberglass Frame 12. Upper Latch 6. Ball Stud 13. Latch Plate 7. Door Hinges 14. Arm Rest 15. Document Pocket 5 Figure 52-15-01: Composite Forward Door (2C1 & 2C2) 52-15 Page 2
Note: In the text that follows the term "door is closed" refers to when the latch pin is engaged in the latch plate. The term "door is locked" refers to when the "door is latched closed" and the lock pin is also engaged in the handle mechanism. When the forward port door is "key locked" it refers to the forward port door as "latched closed" and the external key lock is operated to the lock position. (1) The forward doors are constructed of structured fiberglass with imbedded aluminum plates for the required hard points such as hinges. The doors are hinged at the forward part of the door structure with two simple metal hinges. The hinge material is stainless steel. (2) A door latch assembly allows the door to be opened from either the inside or the outside when the doors are not locked. Each door is opened and closed from the outside or the inside by a round door knob which can move fore and aft. The direction of movement to open the door is indicated by an adjacent label. (3) The inside locks are controlled by a lock button located forward of the arm rest. (4) An upper latch assembly is located at the top forward corner of each of the doors. (5) The door can swing fully open and stop against the fuselage. The door is held in this fully open position by a ball stud mounted on the lower surface of the outer door. The ball stud fits into a receptacle on the fuselage. (6) The door has an L-shaped bubble window formed from acrylic plastic. The window thickness is 0.125 inches. The window is held in place with a rubber retaining mount. (7) A document pocket is located on the lower part of the door. (8) A rubber seal for weather protection is mounted around the perimeter inside of the door. The seal is set back from the interior of the door flange to allow It to compress between the door flange and the airframe. This compression ensures a positive weather seal around the perimeter of the door. (9) Each door has an arm rest. The arm rest can be used as a pull handle to help when closing the door. (10) A door latch assembly allows the door to be opened from either inside or outside when the door is not locked. The door can be locked and unlocked from the inside only. (11) The port door features a keyed lock which allows the aircraft interior to be secured from the outside. (12) Labels with operating instructions for the door knobs and lock buttons are located on the inner and outer surfaces near the applicable controls. (13) Each door has two drilled holes located at both of the lower corners of the door. These holes allow any moisture to drain out of the door structure. 52-15 Page 3
Operation Notes: (1) The operation for the forward door on the port side is described. The operation for the forward door on the starboard side is similar. Differences between the two doors will be indicated. (2) This operation begins with the port door closed and locked from the outside with the keyed lock. A. An outside door knob and an inside door knob control the sliding movement of the latch mechanism. The door knobs move forward to open the door. Labels marked OPEN DOOR with an indicator arrow are located near the door knobs to indicate the movement required to open the door. B The key, when inserted into the door lock and turned in the appropriate direction, will unlock the port door. Slide the outer door knob forward and the door will unlatch and open. The door can now swing fully open. The door stud located on the outer door will engage the receptacle located on the fuselage. This allows the door to be held in the fully open position. CAUTION: Make sure the door latching handle is in the open position when the door is pulled to the closed position. If you do not do this you can cause damage to the door latch pin and structure. C. When the door is closed and locked from the inside, the lock button must be raised, as indicated by the adjacent label to unlock the door. The inner door knob is moved forward and the door will unlatch and open. When the inner door knob is released it will go to the door latched position. The latch pin is spring loaded to the door latched (latch pin extended) position. D. To close the door, hold the door knob in the forward position and use the integrated door pull handle / arm rest to pull the door to the closed position. Move the door knob to the rear position. The door is now latched. Push the lock button down and the door is locked. E. The forward door is held in the closed position by a sliding latch pin located on the aft end of the door frame. The sliding latch pin extends into a latch plate located on the aft vertical door-jamb. F. An upper latch assembly is located on the inside of each forward door at the top of the door frame. This latch assembly can only be operated from the inside of the aircraft. The latch is rotated to engage an upper latch plate mounted on the door-jamb. This latch pulls the top end of the door inboard. G. The L-shaped windows in the doors are bubble shaped to allow for greater visibility and increased shoulder room. H. External Security Key Lock CAUTION: Make sure the lock button on the inside of the door is in the unlock position before the door is closed. If you fail to do this you can cause damage to the door lock mechanism. 52-15 Page 4
I. An external key operated lock is featured only on the port (pilot's side) door. This feature allows the port door to be locked after the other doors are locked from the inside. This provides security to the aircraft interior and operates as follows: (1) The key is inserted into the lock before the door is closed. (2) The door is closed and latched close. (3) The key is turned to the locked position. Note: The door is now latched closed and the key lock is engaged. (4) The key is removed from the lock. Note: To ensure complete security of the aircraft interior, the forward, starboard door and the two cargo doors must be manually locked from the inside. The keyed lock will secure the forward port door only. J. Freeze Protection The door has two drain holes located at each of the bottom corners of the Door to allow moisture to go overboard. 52-15 Page 5
52-15-10 Forward Door Removal and Installation (2C1 and 2C2) The maintenance procedures that follow are for the removal and installation of the forward doors. There is a forward door installed on either side of the aircraft. The procedure for the port forward door is described; the starboard forward door is similar. Differences that exist will be indicated. Refer to Figure 52-15-02. Forward Door Removal Step 1. Open the forward upper latch assembly. Note: The upper latch assembly is located on the inner door at the forward top of the door. Step 2. Remove and discard the cotter pins (1) and (10). Step 3. Remove the washers (2) and (9). Step 4. Open the door and support the weight of the door. Step 5. Remove the pin (3) and the washer (4) from the upper hinge assembly (5) and (11). Step 6. Remove the pin (8) and the washer (7) from the lower hinge assembly (6) and (12). CAUTION: Make sure the door is moved clear of the hinges before rotating the door. If you do not do this you can cause damage to the door hinges. Step 7. Move the door away from the hinge-half (5) and the hinge-half (6) without rotating the door until it is clear of the hinges. CAUTION: Make sure the door is put in an area where the door and the clear surface of the bubble window will not be damaged. If you do not do this you can cause damage to the door and the bubble window surface. Step 8. Move the door to an area where the door surface and the surface of the bubble window will not be damaged. 52-15 Page 6
5 3 4 11 2 1 6 7 8 12 9 10 Figure 52-15-02: Composite Forward Door Removal/Installation (2C1 & 2C2) 52-15 Page 7
Forward Door Installation Step 9. Support the door and install the hinge-half (11) and hinge-half (12) over the hinge-half (5) and the hinge-half (6). Step 10. Install the pin (3) with the washer (4) into the upper hinge assembly (5) and (11). Step 11. Install the pin (8) with the washer (7) into the lower hinge assembly (6) and (12). Step 12. Close and latch the forward door. Step 13. Install the washer (2) with the cotter pin (1) in the pin (3). Step 14. Install the washer (9) with the cotter pin (10) in the pin (8). Step 15. Safety the cotter pin (1) and the cotter pin (10). Step 16. Open and close the door to ensure door does not bind and the latch and locks operate correctly. Step 17. On the port door only, carry out an operational check of the keyed lock. 52-15 Page 8
52-17 COMPOSITE FORWARD DOORS (2C3 & 2C4) 52-17-00 General Two doors in the forward cabin provide access for the pilot and the co-pilot. The basic door structure is a composite construction of 5.7 oz/sq-yd carbon cloth and epoxy resin. The large panels on the door are sandwich laminates with 6 mm thick Divinycell foam as the core material. The required hard points such as hinges and latch mount are reinforced with multiple layers of carbon fiber. The door has an L -shaped window formed from acrylic plastic. The window thickness is 0.125 inches. The window is bonded to the composite door structure. The doors are attached to the composite side skins on the fuselage with two machined aluminum hinges. The hinges are anodizes for corrosion protection. The hinges are handed for the left and right doors but are common to the aft doors. An automotive type door latch assembly allows the door to be opened from either the inside or the outside. The door can be opened from the inside even with the external security lock engaged. Each door is opened from the outside or the inside by an automotive type pull handle. The automotive style handles and door latches are handed for the left and right doors but are common to the aft doors. Both doors are equipped with external keyed security locks. To secure the aircraft on the ground the pilot must use a key to lock each door. There are no internal security locks on the doors The door can swing fully open and is held in this fully open position by a gas shock mounted on the upper surface of the door and the upper surface of the door frame. A rubber-type seal for weather protection is mounted around the perimeter of the opening in the fuselage. The seal is set back from the interior of the door to allow it to compress between the door and the airframe. This compression ensures a positive weather seal around the perimeter of the door. Each door has an arm rest. The arm rest can be used as a pull handle to help when closing the door. Each door has drilled holes located along the lower surface of the door. These holes allow any moisture to drain out of the door structure. Refer to Figure 52-17-01A & 52-17-01B 52-17 Page 1
UPPER HINGE A B EXTERIOR HANDLE INTERIOR HANDLE WEATHER SEAL A KEY LOCK LOWER HINGE VIEW ON PORT DOOR (EXTERNAL VIEW) DOOR FRAME HINGE SEGMENT CLEVIS PIN WASHER HINGE SEGMENT COTTER PIN FUSELAGE SIDE SHELL DETAIL A 52-17-01A: Forward Door (2C3 & 2C4) 52-17 Page 2
RETAINER CLIP GAS SHOCK VIEW ON ARROW B 52-17-01B: Forward Door (2C3 & 2C4) 52-17 Page 3
52-17-10 Door Removal and Installation Refer to Figure 52-17-01A & 52-17-01B. Forward Door Removal Step 1. Open the door. Step 2. Remove the lock retainer clip from the gas shock Step 3. Disconnect the gas shock from the door. Step 4. Remove and discard the cotter pins from the door hinge pins. Step 5. Support the weight of the door. Step 6. Remove the pin and the washer from the upper hinge. Step 7. Remove the pin and the washer from the lower hinge. Step 8. Move the door away from the upper and lower hinge-halves. CAUTION: Make sure the door is placed in an area where the door and the clear surface of the window will not be damaged. If you do not do this you can cause damage to the door and the window surface. Step 9. Move the door to an area where the door surface and the surface of the window will not be damaged. Forward Door Installation Step 1. Support the door and install the Upper hinge-half and Lower hinge-half of the door over the Upper hinge-half and the Lower hinge-half on the Door Frame. Step 2. Install the pin with the washer into the upper hinge. Step 3. Install the pin with the washer into the lower hinge. Step 4. Attach the gas shock to the door Step 5. Close and latch the forward door. Step 6. Install a new cotter pin in the upper hinge pin. 52-17 Page 4
Step 7. Install a new cotter pin in the lower hinge pin. Step 8. Safety the cotter pins. Step 9. Carry out a function check. 52-17-20 Interior Handle Refer to Figure 52-17-02. Removal: Note: Step 1. Step 2. Step 3. Step 4. The interior handle is fastened to the interior access panel Remove the interior access panel.. Remove the clevis pin and nylon washers from the interior handle bellcrank, discard cotter pin. Remove the screw that fastens the interior handle to the access panel. Remove the interior handle from the access panel. Installation of the interior handle is accomplished by reversing the removal steps above. Carry out a function check after installation. 52-17 Page 5
INTERIOR ACCESS PANEL DOOR CLEVIS PIN NYLON WASHER CABLE EYELET NYLON WASHER (BETWEEN CABLE EYELET AND HANDLE ARM) INTERIOR HANDLE HANDLE BELLCRANK NYLON WASHER COTTER PIN Figure 52-17-02: Interior Handle (2C3 & 2C4) 52-17 Page 6
52-17-30 Exterior Handle Refer to Figure 52-17-03. Removal: Note: Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. The interior handle is fastened to the interior access panel Remove the interior access panel and secure it away from the opening. Do not disconnect the cable from the interior handle. Remove the clevis pin and washers from the exterior handle bellcrank, discard cotter pin. Remove the clevis pin that connects the lock strap to the lock cylinder bellcrank, discard cotter pin. Slide the lock strap away from the lock cylinder bellcrank. Removed the nuts, washers and retainer bracket from the exterior handle. Remove the exterior handle. Installation of the exterior handle is accomplished by reversing the removal steps above. Carry out a function check after installation. 52-17 Page 7
NYLON WASHER COTTER PIN NYLON WASHER EXTERIOR HANDLE BELLCRANK LOCK STRAP WASHER CLEVIS PIN LOCK CYLINDER BELLCRANK CLEVIS PIN CABLE EYELET LOCK CYLINDER BELLCRANK EXTERIOR HANDLE THIN WASHER NUT RETAINER BRACKET Figure 52-17-03: Exterior Handle (2C3 & 2C4) 52-17 Page 8
52-17-40 Door Latch Assembly Refer to Figure 52-17-04 Removal: Step 1. Remove the exterior handle. Ref. 52-17-30. Step 2. Disconnect interior handle cable from the interior handle, see 52-17-20 Step 2 Step 3. Step 4. Step 5. Step 6. Step 7. Remove the Guide Pipe from the standoff bonded to the composite door. Remove the Guide Pipe from the standoff located on the access panel. Remove the hardware securing the latch assembly to the door. Slide the latch assembly over to the access panel opening and maneuver the latch over the cable standoff. Remove the latch assembly from the door. Installation of the latch assembly is accomplished by reversing the removal steps above. Bolts securing the latch assembly to composite door shall be installed wet with primer to reduce a chance of galvanic corrosion. 52-17 Page 9
THIN WASHER BOLT STANDOFF DOOR BOLT THIN WASHER GUIDE PIPE LATCH ASSEMBLY GUIDE PIPE (LOCATED ON ACCESS PANEL) Figure 52-17-04: Door Latch Assembly Removal and Installation (2C3 & 2C4) 52-17 Page 10
52-17-50 Exterior Handle Cable Assembly Replacement Refer to Figure 52-17-05. Step 1. Remove door latch assembly, Ref. 52-17-40. Step 2. Remove the bolt, nut, and washers used to secure the eyelet of the cable to the latch. Step 3. Remove & discard the old cable. Step 4. Attach the new cable to the latch. Step 5. Attach the new cable to the exterior handle.. Step 6. Install door latch assembly, Ref. 52-17-40. Step 7. Carry out a function check. NUT NYLON WASHER NYLON WASHER EXTERIOR HANDLE CABLE ASSEMBLY NYLON WASHER LATCH ASSEMBLY BOLT Figure 52-17-05: Exterior Handle Cable Assembly Replacement (2C3 & 2C4) 52-17 Page 11
52-17-55 Interior Handle Cable Replacement Refer to Figure 52-17-06. Step 1. Remove the internal access panel. Step 2. Remove the hardware securing the cable eyelet. Scrap cotter pin. Step 3. Remove hardware securing the other end of cable. Scrap the cotter pin. Step 4. Attach a new cable assembly. Step 5. Install the latch assembly, Ref. 52-17-40 Step 6. Install internal access panel. Step 7. Carry out a function check. 52-17 Page 12
COTTER PIN NYLON WASHER CABLE EYELET INTERIOR HANDLE CABLE ASSEMBLY LATCH ASSEMBLY CLIP BUSHING CLEVIS PIN Figure 52-17-06: Interior Handle Cable Assembly Replacement (2C3 & 2C4) 52-17-60 Interior Handle Cable Adjustment Refer to Figure 52-17-07. CAUTION: Do not over tighten the cables while adjusting. This will cause the latch to release very easily. This will also cause excess friction in the system and possible premature wear of the cable/casing. Step 1. Remove interior access panel. Step 2. Turn the adjusting barrel on the Guide Pipe at the Interior Handle and/or the Guide Pipe at the latch release lever. Step 3. Carry out operational check. If the latch does not release when the handle has moved through half of its range, repeat Step 2. 52-17 Page 13
52-17-65 Exterior Handle Cable Adjustment Refer to Figure 52-17-07. CAUTION: Do not over tighten the cables while adjusting. This will cause the latch to release very easily. This will also cause excess friction in the system and possible premature wear of the cable/casing. Step 1. Remove interior access panel. Step 2. Loosen the jam nuts on the adjustment barrel. Step 3. Hold the jam nuts and turn the adjusting barrel. Step 4. Carry out operational test. If the latch does not release when the handle has moved through half of its range, repeat Step 3-4. Step 5. Tighten jam nuts once adjustment is completed. 52-17 Page 14
CABLE ADJUSTER & JAM NUTS INTERIOR ACCESS PANEL CABLE ADJUSTING BARREL DOOR CABLE ADJUSTING BARREL JAM NUTS CABLE ADJUSTER Figure 52-17-07: Cable Adjustment (2C3 & 2C4) 52-17 Page 15
52-17-70 Gas Shock Replacement Refer to Figure 52-17-08. Step 1. Remove the retainer clips from both ends of the gas shock. Step 2. Disconnect the gas shock from the studs. Step 3. Remove the nylon plug from the door to gain access to the nut. Step 4. Remove the nut. The mounting stud is free from the door. Step 5. Remove the Eyeball vent and interior panel from the cabin area. Step 6. Remove the mounting stud from the door frame. Step 7. Replace the ball studs on the door and the door frame. Step 8. Connect the gas shock to both ball studs. Step 9. Insert Retainer Clips in both ends of the gas shock. Step 10. Carry out an operational check. Step 11. Install interior panel, eyeball vent and thee nylon plug. 52-17-75 Hinge Replacement Refer to Figure 52-17-08. Step 1. Remove the door, see 52-17-10. Step 2. Remove bushing from hinge segment (door frame hinge segment only). Step 3. Mark the location of the hinge segment on the door or the door frame depending on which item is being replaced. Step 4. Remove the countersunk screws and discard the old hinge segment. Step 5. Install bushing in the new hinge segment (door frame hinge segment only). Step 6. Install the new hinge segment. Install screws wet with primer to reduce possibility of galvanic corrosion with carbon door or frame. 52-17-80 Striker Bolt Replacement Refer to Figure 52-17-09. Step 1. Mark the location of the current striker bolt. Step 2. Remove the interior panel. Step 3. Remove the hardware securing the striker bolt and discard the striker bolt. Step 4. Install the new striker bolt in the location marked in Step 1. Install wet with primer to reduce possibility of galvanic corrosion with carbon frame. Step 5. Install the hardware to secure the striker bolt to the composite door frame. Step 6. Carry out a function check. 52-17 Page 16
52-17-85 Door Seal Replacement Refer to Figure 52-17-09. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Remove old door seal by pulling it away from the door frame. Clean door seal mating area with isopropyl alcohol Start the new door seal near the mounting stud for the gas shock. Leave the end of the door seal hanging down 2 to 3 inches from perimeter. Bend the door seal back enough to open the split. This will ease installation. Work the door seal around the perimeter of the door. Leave 2 to 3 inches of the door seal hanging down from perimeter. Bring the two loose ends of the door seal up to the door frame until they touch and slide them onto the door frame flange. Smooth out any excess door seal toward the ends and remove excess material if required. After installation, clean door seal with a cloth slightly dampened with isopropyl alcohol. 52-17 Page 17
WASHER RETAINER CLIP NYLON PLUG COUNTERSUNK SCREWS COUNTERSUNK SCREWS VIEW ON ARROW B GAS SHOCK C LOCK NUT WASHER UPPER HINGE SEGMENT DOOR SEAL BUSHING BALL STUD LOWER HINGE SEGMENT OUTBRD VIEW ON ARROW C Figure 52-17-08: Gas Shock & Hinge Replacement (2C3 & 2C4) 52-17 Page 18
WASHER LOCK NUT COMPOSITE DOOR FRAME STRIKER BOLT DOOR SEAL GAS SHOCK BALL STUD DETAIL D D Figure 52-17-09: Door Seal & Striker Bolt Replacement (2C3 & 2C4) 52-17 Page 19
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52-30 ALUMINUM AFT DOORS (2C1) 52-30-00 General Both aft doors are hinged at the forward side at Arm 34 with three simple hinges. A latch mechanism allows the door to be opened from either inside or outside, but may be manually locked from the inside only. Door Removal and Installation The aft doors may be removed while in the opened or closed position. The doors may be removed with the flaps in any position. Remove the cotter pins in the three hinge pins and withdraw the hinge pins. To install aft door reverse above steps. 52-30-10 Aft Door Hinges There are three hinges on the aft doors, all three are interchangeable. Hinge Removal and Installation If hinges are to be removed with the door closed, replace only one hinge at a time. If all hinges must be removed at the same time, ensure the door is secured into the door frame, or is supported in such a manner that it does not fall free. Remove the cotter pin in the hinge pin and withdraw the hinge pin. Remove the four screws which hold the hinge to the fuselage or door. To install hinge reverse above steps. 52-30-20 Aft Door Latch Each of the aft door latches serve as a means to secure the door in the closed position and to provide a means of locking the door. See Figure 52-30-01. To secure the door from inside, or to lock the door, the lock knob is rotated which prevents the latch mechanism from moving. Each of the aft doors has two latch pins. One is located at the top aft corner, the other is located at the lower aft corner. See Figure 52-30-01. 52-30 Page 1
Figure 52-30-01: Aluminum Aft Door Latch (2C1) 52-30 Page 2
52-30-21 Aft Door Latch Adjustments When the door is closed and latched, the full diameter of the latch pin must penetrate the latch pin socket in the door frame by a minimum of 0.250. Step 1. Remove the inside door panel to gain access to the latch pin adjustments. Step 2. Loosen off the jamb nut on the end of the latch pin. Step 3. Turn the latch pin the required direction then tighten the jamb nut. Step 4. Close and latch the door to ensure correct depth in door frame. 52-30 Page 3 July28, 2008
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52-35 COMPOSITE AFT DOORS (2C1 AND 2C2) 52-35-00 General The two aft doors shall be referred to as the cargo doors. The two cargo doors provide access for three passengers and or cargo. The port cargo door is described. The starboard door is similar. Differences between the doors will be indicated. Description Refer to Figure 52-35-01 and Figure 52-35-02. A. Features of each cargo door are as follows: - structured fiberglass construction for strength and durability. - large "L-shaped" bubble windows. - extra shoulder room due to bubble windows. - arm rests on the forward doors. - interiors which feature durable trim panels. - doors that may be latched and locked from the inside and opened from the outside when the door is not locked. - labels with operating instructions for the door knobs and lock buttons. - maintenance access panels - a rubber perimeter seal. - document pockets - stainless steel door hinges - some interchangeable door hinges - drain holes on the lower parts of the door - door pull handle B. (1) The cargo door is constructed of structured fiberglass with imbedded metal for required hard points such as hinges. (2) The door is hinged at the forward part of the door structure with three simple metal hinges. The hinge material is stainless steel. (3) The door can swing open and stop against the fuselage. A check strap is located above the lowest hinge of the door. This check strap is used to stop the aft door from hitting the forward door when both doors are opening. (4) The door has a rubber mounted L-shaped bubble window formed from acrylic plastic. The window thickness is 0.125 inches. The windows are held in place with a rubber retaining mount. (5) A rubber seal for weather protection is mounted inside of the door flange around the perimeter of each door. 52-35 Page 1
(6) A door latch assembly allows the door to be opened from either the inside or the outside when the doors are not locked. A spring in the door latching mechanism maintains pressure on the door latch pins when the door is latched closed. (7) The door can only be locked from the inside. (8) Labels with operating instructions for the door knobs and lock buttons are on the inner and outer surfaces near the applicable controls. (9) The door is opened from the outside with a rotating knob. (10) The door is opened from the inside by a latch (door) handle which moves in an arc forward and aft. (11) The lock button is located on the side panel near the latch handle. (12) A document pocket is located on the lower section of the inner door. 52-35 Page 2
5 5 1 LEGEND 1. Bubble Window 2. Label 3. Door Knob 4. Fiberglass Frame 5. Door Hinges 5 4 LEGEND Continued 6. Door Knob 7. Door Lock Knob 8. Labels 9. Fiberglass Frame 10. Bubble WIndow 11. Access Panel 12. Perimeter Seal 13. Document Pocket 14. Restraint Strap 15. Latch Pins 16. Access Panels 17. Plastic Caps 18. Door Handle Figure 52-35-01: Composite Aft Door Description (2C1 & 2C2) 52-35 Page 3
Detail A Restraint Strap Access Panel Inside Door Handle Door Pull Handle Figure 52-35-02: Fiberglass Aft Door Description (2C1 & 2C2) 52-35 Page 4
Operation Refer to Figure 52-35-01 and Figure 52-35-02. Notes: (1) The operation for the cargo door on the port side is described. The operation for the cargo door on the starboard side is similar. Differences between the two doors will be indicated. (2) The operation that follows begins with the internal lock engaged on the cargo doors. A. Gain access through a forward door and enter the aft compartment. Move the inside lock button, located below the latch handle, to the unlock position as indicated by the adjacent label. Move the door latch handle to the open (rear) position, as indicated by the adjacent label. The door will now be unlatched and can open. B. Movement of the latch handle to the OPEN position will actuate the mechanism of push-rods and bell cranks and move the vertical latch pins out of the latch plates. The door can now open. The latch pins will remain out of the latch plates until the latch handle is moved to the closed (forward) position. C. If the door is closed (latched) and not locked from the inside do as follows (1) Rotate the outer door knob in the direction indicated by the adjacent label. The door will unlatch and can open. (2) Pull the door and swing it open. Note: The door will be restricted from moving against the fuselage by a restraint located above the lower door hinge. strap CAUTION: Make sure the door latch handle is in the door open position before closing the door. If you do not do this you can cause the damage to the door latch pins and the structure. D. Make sure the door latch handle is in the open position. To latch and lock the door from inside use the door pull handle to move the door to the closed position. Move the latch handle to the closed (forward) position as indicated by the label. Release the door pull handle. The latch pins are now in the latch plates and the door is latched closed. Move the door lock knob to the locked position as indicated on the label and the door is locked. 52-35-10 Removal and Installation The maintenance procedures that follow are for the removal and installation of the cargo (aft) doors. In the text that follows, the term "door" refers to the cargo door. There is a cargo door installed on either side of the aircraft. The procedure for the port door is described, the starboard door is similar. Differences that exist between the doors will be indicated. 52-35 Page 5
Refer to Figure 52-35-03. Aft Door Removal Step 1. Remove and discard the cotter pins (1), (5) and (9). Step 2. Remove the washers (2), (6) and (10). Step 3. Remove the pin (7) and the washer (8). Step 4. Open and support the door. Step 5. Remove the pin (11) and the washer (12). Step 6. Remove the pin (3) and the washer (4). CAUTION: Make sure the door is moved clear of the hinges before rotating the door. If you do not do this you can cause damage to the door hinges. Step 7. Move the door away from the hinge-half (13), the hinge-half (15) and the hinge-half (17) without rotating the door until it is clear of the opposite hinge-halves. CAUTION: Make sure the door is put in an area where the door surface and bubble window will not be damaged. If you do not do this you can cause damage to the door and the bubble window surface. Step 8. Move the door to an area where the door surface and the surface of the bubble window will not be damaged. Aft Door Installation Step 1. Support the door and install the hinge-half (14), hinge-half (16) and hinge-half (18) over the hinge-half (13), hinge-half (15) and hinge-half (17). Step 2. Install the pin (3) with the washer (4) into the upper hinge assembly (13) and (14). Step 3. Install the pin (7) with the washer (8) into the centre hinge assembly (15) and (16). Step 4. Install the pin (11) with the washer (12) into the lower hinge assembly (17) and (18). Step 5. Install the washer (2) with the cotter pin (1) in the pin (3). Step 6. Install the washer (6) and the cotter pin (5) in the pin (7). Step 7. Install the washer (10) and the cotter pin (9) in the pin (11). Step 8. Safety the cotter pin (1) the cotter pin (5) and the cotter pin (9). Step 9. Attach the door restraint strap to the fuselage attachment hook. Step 10. Open and close the door to ensure the door does not bind and the latch and locks operate correctly. 52-35 Page 6
3 4 14 2 7 8 1 15 6 17 11 12 18 10 9 Figure 52-35-03: Fiberglass Aft Door Removal/Installation (2C1 & 2C2) 52-35 Page 7
INTENTIONALLY LEFT BLANK 52-35 Page 8
52-37 COMPOSITE AFT DOORS (2C3 & 2C4) 52-37-00 General The two aft doors also referred to as the cargo doors provide access to the passenger compartment and baggage area. The aft door construction and mechanisms are essentially the same as the front doors; refer to section 52-17 for a complete description. UPPER HINGE A EXTERIOR HANDLE INTERIOR HANDLE A LOWER HINGE KEY LOCK DOOR FRAME HINGE SEGMENT CLEVIS PIN WASHER HINGE SEGMENT COTTER PIN FUSELAGE SIDE SHELL DETAIL A Figure 52-37-01: Composite Aft Door (2C3 & 2C4) 52-37 Page 1
52-37-10 Door Removal and Installation Refer to Figure 52-17-01A & 52-17-01B. Forward Door Removal Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Open the door. Remove the lock retainer clip from the gas shock Disconnect the gas shock from the door. Remove and discard the cotter pins from the door hinge pins. Support the weight of the door. Remove the pin and the washer from the upper hinge. Remove the pin and the washer from the lower hinge. Move the door away from the upper and lower hinge-halves. CAUTION: Make sure the door is put in an area where the door and the clear surface of the window will not be damaged. If you do not do this you can cause damage to the door and the window surface. Step 9. Move the door to an area where the door surface and the surface of the window will not be damaged. Cargo Door Installation Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Support the door and install the Upper hinge-half and Lower hinge-half of the door over the Upper hinge-half and the Lower hinge-half on the Door Frame. Install the pin with the washer into the upper hinge. Install the pin with the washer into the lower hinge. Attach the gas shock to the door Close and latch the forward door. Install a new cotter pin in the upper hinge pin. 52-37 Page 2
Step 7. Step 8. Step 9. Install a new cotter pin in the lower hinge pin. Safety the cotter pins. Carry out a function check. 52-37-20 Interior Handle Refer to Figure 52-17-02. Removal: Note: The interior handle is fastened to the interior access panel Step 1. Remove the interior access panel.. Step 2. Remove the clevis pin and nylon washers from the interior handle bellcrank, discard cotter pin. Step 3. Remove the screw that fastens the interior handle to the access panel. Step 4. Remove the interior handle from the access panel. Installation of the interior handle is accomplished by reversing the removal steps above. Carry out a function check after installation. 52-37-30 Exterior Handle Refer to Figure 52-17-03. Removal: Note: The interior handle is fastened to the interior access panel Step 1. Remove the interior access panel and secure it away from the opening. Do not disconnect the cable from the interior handle. Step 2. Remove the clevis pin and washers from the exterior handle bellcrank, discard cotter pin. 52-37 Page 3
Step 3. Remove the clevis pin that connects the lock strap to the lock cylinder bellcrank, discard cotter pin. Step 4. Slide the lock strap away from the lock cylinder bellcrank. Step 5. Removed the nuts, washers and retainer bracket from the exterior handle. Step 6. Remove the exterior handle. Installation of the exterior handle is accomplished by reversing the removal steps above. Carry out a function check after installation. 52-37-40 Door Latch Assembly Refer to Figure 52-17-04 Removal: Step 1. Remove the exterior handle. Ref. 52-17-30. Step 2. Disconnect interior handle cable from the interior handle, see 52-37-20 Step 2 Step 3. Remove the Guide Pipe from the standoff bonded to the composite door. Step 4. Remove the Guide Pipe from the standoff located on the access panel. Step 5. Remove the hardware securing the latch assembly to the door. Step 6. Slide the latch assembly over to the access panel opening and maneuver the latch over the cable standoff. Step 7. Remove the latch assembly from the door. Installation of the latch assembly is accomplished by reversing the removal steps above. Bolts securing the latch assembly to composite door shall be installed wet with primer to reduce a chance of galvanic corrosion. 52-37 Page 4
52-37-50 Exterior Handle Cable Assembly Replacement Refer to Figure 52-17-05. Step 1. Remove door latch assembly, Ref. 52-17-40. Step 2. Remove the bolt, nut, and washers used to secure the eyelet of the cable to the latch. Step 3. Remove & discard the old cable. Step 4. Attach the new cable to the latch. Step 5. Attach the new cable to the exterior handle.. Step 6. Install door latch assembly, Ref. 52-17-40. Step 7. Carry out a function check 52-37-55 Interior Handle Cable Replacement Refer to Figure 52-17-06. Step 1. Remove the internal access panel. Step 2. Remove the hardware securing the cable eyelet. Scrap cotter pin. Step 3. Remove the door latch assembly, Ref. 52-17-40. Step 4. Remove hardware securing the other end of cable. Scrap the cotter pin. Step 5. Attach a new cable assembly. Step 6. Install the latch assembly, Ref. 52-17-40 Step 7. Install internal access panel. Step 8. Carry out a function check 52-37 Page 5
52-37-60 Interior Handle Cable Adjustment Refer to Figure 52-17-07. CAUTION: Do not over tighten the cables while adjusting. This will cause the latch to release very easily. This will also cause excess friction in the system and possible premature wear of the cable/casing. Step 1. Remove interior access panel. Step 2. Turn the adjusting barrel on the Guide Pipe at the Interior Handle and/or the Guide Pipe at the latch release lever. Step 3. Carry out operational test. If the latch does not release when the handle has moved through half of its range, repeat Step 2. 52-37 Page 6
52-37-65 Exterior Handle Cable Adjustment Refer to Figure 52-17-07. CAUTION: Do not over tighten the cables while adjusting. This will cause the latch to release very easily. This will also cause excess friction in the system and possible premature wear of the cable/casing. Step 1. Remove interior access panel. Step 2. Loosen the jam nuts on the adjustment barrel. Step 3. Hold the jam nuts and turn the adjusting barrel. Step 4. Carryout operational test. If the latch does not release when the handle has moved through half of its range, repeat Step 3-4. Step 5. Tighten jam nuts once adjustment is completed. 52-37-70 Gas Shock Replacement Refer to Figure 52-17-08. Step 1. Remove the retainer clips from both ends of the gas shock. Step 2. Disconnect the gas shock from the studs. Step 3. Remove the nylon plug from the door to gain access to the nut. Step 4. Remove the nut. The mounting stud is free from the door. Step 5. Remove the Eyeball vent and interior panel from the cabin area. Step 6. Remove the mounting stud from the door frame. Step 7. Replace the ball studs on the door and the door frame. Step 8. Connect the gas shock to both ball studs. Step 9. Insert Retainer Clips in both ends of the gas shock. Step 10. Carry out operational check. Step 11. Install interior panel, eyeball vent and thee nylon plug. 52-37-75 Hinge Replacement Refer to Figure 52-17-08. Step 1. Remove the door, see 53-37-10. Step 2. Remove bushing from hinge segment (door frame hinge segment only). Step 3. Mark the location of the hinge segment on the door or the door frame depending on which item is being replaced Step 4. Remove the countersunk screws and discard the old hinge segment Step 5. Install bushing in the new hinge segment (door frame hinge segment only). 52-37 Page 7
Step 6. Install the new hinge segment. Install screws wet with primer to reduce possibility of galvanic corrosion with carbon door or frame. 52-37-80 Striker Bolt Replacement Refer to Figure 52-17-09. Step 1. Mark the location of the current striker bolt. Step 2. Remove the interior panel. Step 3. Remove the hardware securing the striker bolt and discard the striker bolt. Step 4. Install the new striker bolt in the location marked in Step 1. Install wet with primer to reduce possibility of galvanic corrosion with carbon frame. Step 5. Install the hardware to secure the striker bolt to the composite door frame. Step 6. Carry out a function check. 52-37-85 Door Seal Replacement Refer to Figure 52-17-09. Step 1. Remove old door seal by pulling it away from the door frame. Step 2. Clean door seal mating area with isopropyl alcohol. Step 3. Start the new door seal near the mounting stud for the gas shock. Leave the end of the door seal hanging down 2 to 3 inches from perimeter. Step 4. Bend the door seal back enough to open the split. This will ease installation. Work the door seal around the perimeter of the door. Leave 2 to 3 inches of the door seal hanging down from perimeter. Step 5. Bring the two loose ends of the door seal up to the door frame until they touch and slide them onto the door frame flange. Step 6. Smooth out any excess door seal toward the ends and remove excess material if required. Step 7. After installation, clean door seal with a cloth slightly dampened with isopropyl alcohol. 52-37 Page 8