Forward Airstair Door Lock Mechanism  500 
52-61-531 Page 404  Figure 401 (Sheet 3) BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  Nov 15/68 

500  Forward Airstair Door Lock Mechanism 
Nov 15/68  Figure 401 (Sheet 4) BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  52-61-531 Page 405 

(4)  
Remove bolt, washer and locknut connecting rod-end bearing to the exterior control handle linkage. (Fig. 401, View 1)

(5)  
Remove exterior control handle (if required).

(a)  
Disconnect electrical connector from control handle control box.

(b)  
Remove twelve bolts, washers and locknuts attaching control handle housing to airplane structure.

(c)  
Remove sealant around handle housing and remove control handle assembly.

NOTE:  Refer to Chapter 51, Seals and Sealing for procedures to remove the pressure sealant.
(6)  
Remove rod end bearing and threaded-end fitting from telescoping unit connected to exterior control handle. (Detail A)

(7)  
Compress telescopic unit and remove cable lock from exposed cable.

(8)  
Remove cotter pin, nut, washer and bolt connecting aft end of airstair door lock pin rocker arm to fork-end fitting of telescoping unit, and remove fork-end fitting. (Sec. A-A)

(9)  
Pull cable from telescoping unit until cable lock emerges and remove cable lock from cable.

(10)
Remove control cable from cable casing.

CAUTION:  USE CARE TO KEEP CABLE CLEAN AND FREE OF KINKS IF CABLE IS TO BE REINSTALLED.

(11)
Remove telescoping unit (if required, 2 places).

(a)  
Disconnect casing from base of telescoping unit. (Detail B)

(b)  
Remove jam nuts from base of telescoping unit noting position of washers, and remove telescoping unit.

(12)
Remove control cable casing (if required).

(a)  
Unscrew connectors at each end of casing section to be removed.

(b)
Release tubing clamps securing casing to structure, and remove casing.

500 
52-61-531 Page 406  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  Nov 15/68 

D.  Install Exterior Control Assembly
(1)  
Install control cable casing (if removed).

(a)  
Place sections of casing in position; orient-casing sections in accordance with markings etched on surface of casing.

NOTE:  One end of each casing section is marked FWD with an arrow to indicate orientation.

(b)  
Join connectors at each end of casing section being installed; tighten connectors after all components have been assembled.

(c)  
Install casing clamps securing sections of casing to structure.

(2)  
Install telescoping units (if removed, 2 places).

(a)  
Position telescoping unit and washers on mounting bracket and secure with jam nuts.

NOTE:  Telescoping unit adjacent to rocker arm is spring-loaded in the extend position and installed with AN960PU1016 washer on upper side of bracket and AN960PD1016L washer on lower side of bracket. The telescoping unit adjacent to the control handle is not spring-loaded and installed with AN960PD1016 washer on forward side of bracket.

(b)  
Join casing to telescoping unit and tighten connector.

(3)  
Install control cable.

(a)  
Prior to installation of cable, hand lubricate cable assembly with grease (BMS 3-24).

(b)  
Insert end of cable into opening of telescoping unit and push cable through casing.

CAUTION:  USE CARE TO KEEP CABLE CLEAN AND PREVENT KINKING OF CABLE.

(c)  
Install cable lock on end of cable at telescopic unit adjacent to rocker arm so that cable extends 0.60 (+ 0.05/- 0.05) inch past cable lock and push cable into telescoping unit to seat cable lock. (Sec. A-A)

(d)  
Screw fork-end fitting into telescoping unit and torque to 200 pound-inches. Check that cable is visible at inspection hole in fork-end fitting.

(e)  
Connect fork-end fitting of telescoping unit t o aft end of rocker arm with bolt, washer and nut.

(f)  
Compress telescoping unit adjacent to control handle and install cable lock on end of cable so that cable extends .50 inch past cable lock. Pull telescopic unit to extended position to seat cable lock. (Detail A)

(g)  
Screw threaded-end fitting into telescoping unit and torque to 200 pound-inches. Check that cable is visible at inspection hole in threaded-end fitting.
　
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