52-13-03
 ú ú 01 Page 404 ú Oct 15/98
BOEING PROPRIETARY - Copyright (C) - Unpublished Work - See title page for details.
A
747-400 MAINTENANCE MANUAL
 (b)  
Turn the internal door handle (5) to the open position.

 (c)  
Move the crew service door aft.

 (d)  
Install the safety barrier 6PRE65b00040 in the doorway.

 (e)  
Remove the two capscrews (3) and pin (4) from the internal door handle (5) boss.

 (f)  
Remove the internal door handle (5).

 (g)  
Remove the screws (6), adapter (7), and shim (8) from the cam assembly (9).

 (h)  
Remove the nut (10) and spacer plate (11) from the shaft assembly (12).

 (i)  
Move the crew service door forward until it is almost closed.

 (j)  
Remove the screws (13) from the external door handle (14) and adapter assembly (16).

 (k)  
Remove the external door handle (14).

 (l)  
Remove the fairing plate (15) from the recessed fairing housing (17).

 NOTE: If necessary, carefully cut through any sealant which is
____ used to fill the gap between the fairing plate (15) and the recessed fairing housing (17).
 (m)  
Remove two screws (19), four washers (20, and two spacers (21) from the fairing plate (15) and recessed fairing housing (17).

 (n)  
Remove the shaft assembly (12) and adapter assembly (16) from the mechanism housing (18) bearings.

 NOTE: If necessary, use a steel punch to remove the shaft
____ assembly (12) from the cam assembly (9).
 TASK 52-13-03-424-019
 3. Installation of the Internal/External Door Handles
__________________________________________________
 A. Special Tools and Equipment
 (1)  
Crew Service Door Safety Barrier - 6PRE65B00040

 B.
Consumable Materials

 (1)  
Grease - MIL-G-23827

 (2)  
Sealant - BMS 5-26, class B (Pro-seal 890 only).

 C.
Standard Tools and Equipment

 (1)
Maintenance Stand (necessary to reach the crew service door).

 D.
Access

 (1)  
Location Zone
 223 Fwd Upper Deck LH
 224 Fwd Upper Deck RH

 EFFECTIVITYùùùùùùùùùùùùùùùùùùùùùùùùùùùùùù. FREIGHTERS ONLY ú

 52-13-03
 ú ú 01 Page 405 ú Oct 15/98
BOEING PROPRIETARY - Copyright (C) - Unpublished Work - See title page for details.
A
747-400 MAINTENANCE MANUAL
 E. Procedure
 S 424-048
 (1)  
Install the butterfly external handle assembly
 (configuration 1): (Fig. 401)

 (a)  
Apply the grease to the splines and bearing surfaces of the shaft assembly (12).

 (b)  
Install the external door handle assembly (13) into the mechanism housing (14).

 (c)  
Align the master splines of the shaft assembly (12) and the cam assembly (10).

 (d)  
Push the external door handle assembly (13) through the cam assembly (10).

 (e)  
Assemble the nut (11) on the shaft assembly (12) and tighten it.

 (f)  
Turn the external door handle assembly (13) open and closed two or three times to make sure that the cam assembly (9) is free to move.

 (g)  
Turn the external door handle assembly (13) to the open position.

 (h)  
Make sure the external door handle assembly (13) is properly stowed.

 (i)  
Assemble the internal door handle (9) on the cam assembly (10).

 (j)  
Install the pin (5), washer (4), and cotter pin (3) through the internal door handle (9) boss.

 (k)  
Pull the hinged handles of the external door handle assembly (13) out of the door handle housing (16).

 (l)  
Turn the external door handle assembly (13) to the mid-closed position.

 NOTE: This will move the end of the pushrod in and make it
____ easier to connect the internal door handle (9) to it.
 (m)  
Align the internal door handle (9) holes with the end of the pushrod.

 (n)  
Install the pin (8) through the internal door handle (9) and the pushrod.

 (o)  
Assemble the washer (7) and cotter pin (6) on the pin (8).