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5.  Prepare Forward Airstair Door for Installation (New Unit)
A.  Remove standby motor (Ref. 52-61-591, Removal/Installation).
B.  Check door seals for condition. If required, repair per 52-09-100, Approved Repairs.
C.  Manually move airstair door carriage to inboard end of carriage tracks by rotating the actuator manual drive.
D.  Loosen two bolts securing centering guide fitting to lower sill of door opening (Fig. 401, Detail A).
E.  Remove lock springs from upper guide fittings of door. Screw head of each guide pin approximately two full turns toward guide fitting.
F.  Remove all eight door stop pins (Detail B).
G.  Engage upper guide rollers of door in door tracks and install bolt connecting lower guide fitting of door to door carriage.
H.  Rotate actuator manual drive to move door toward closed position. Stop when surplus edge margin of outboard skin of door contacts inboard surface of skin around door opening.
I.  Install door stop pins at forward and aft lower corners of door and screw outboard until they contact the adjacent bearing plates.
J.  Check that door stop pins are centered on the bearing plates (Fig. 402). If necessary, adjust position of door as follows:
(1)  
Loosen the eight lower guide fitting attachment bolts and move fitting horizontally and/or vertically on its serrations (Fig. 401, Detail A).

(2)  
After positioning door, to center the door stop pins, tighten bolts of lower guide fitting.

K.  With door stop pins centered on their bearing plates, scribe a line around outboard surface of door skin, using door opening as a template.
L.  Manually open door, remove bolt connecting lower guide fitting to carriage, and remove door from airplane.
52-61-500 Aug 15/80 Page 406
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.

500  Forward Airstair Door Centering Adjustment 
Nov 15/67  Figure 402  52-61-500 
Page 407 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

M.  Remove doorstop pins from forward and aft lower corners of door.
N.  Trim material from edge of outboard skin of door using scribed line as a guide.
CAUTION:  UNDER NO CIRCUMSTANCES SHOULD ANY MATERIAL BE TRIMMED FROM THE FUSELAGE SKIN AROUND THE DOOR OPENING.
NOTE:  The allowable gap between the edge of the door skin and edge of the door opening is as follows (Fig. 403):
At top and sides of door -- 0.09 + 0.09/- 0.03 inch At bottom of door -- 0.12 + 0.09/- 0.03 inch
O.  Apply organic corrosion inhibiting compound to exposed areas of interior structure (access through lightening holes) per instructions in 51-21-91.
6.  Install Forward Airstair Door (New Unit)
NOTE:  The following instructions are equally applicable to installing a door, which was previously installed on another airplane.
A.  Accomplish steps A thru G of par. 5, or check that these preparatory steps have been completed.
B.  Manually move door to closed position, stopping when outboard rollers of carriage are in line with 0.25-inch diameter hole at outboard end of carriage tracks (Fig. 401).
NOTE:  As the door approaches closed position it may be necessary to move the centering guide fitting on its serrations to align with centering roller on lower edge of door (Detail A).
C.  Adjust door for flushness with outboard surface of fuselage skin at perimeter of door (Fig. 404).
(1)  
Adjust upper edge of door by loosening screws attaching upper ends of both door tracks to fuselage structure (Detail A).

(2)  
Move each door track the required distance inboard or outboard, as necessary, on its serrated mounting plate. Retighten attachment screws.

(3)  
Adjust lower edge of door by installing door stop pins at forward and aft lower corners of door and screwing each pin against its bearing plate as required.

(4)  
Rotate each doorstop pin to align one of its grooves with nearest groove in bushing and install lock spring (Detail B, Fig. 401).

501 
52-61-500 Page 408  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  Feb 01/76 

+ 
500 Nov 15/67  Forward Airstair Door Edge Tolerance Figure 403 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  52-61-500 Page 409 

Forward Airstair Door Flushness Adjustment  500 
52-61-500  Figure 404 (Sheet 1)  Nov 15/68 
Page 410 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

501  Forward Airstair Door Flushness Adjustment 
　
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