C&D Aerospace B221200 Cockpit Door Assembly Component Maintenance Manual 52-51-06 – Boeing 737/757 PDF

Description

The C&D Aerospace B221200 Cockpit Door Assembly Component Maintenance Manual (document 52-51-06) is the shop-level maintenance reference for the fortified flight deck door installed on Boeing 737 and Boeing 757 aircraft. Revision 5, dated Feb 27/04, is a full re-issue of the manual that adds the B221200-531 and B221200-533 configurations, revised fault isolation procedures, a new cleaning and lubrication procedure for the door latch assembly, Loctite threadlocker application instructions, and the deadbolt armor plate installation introduced by Service Bulletin B221200-52-01. Every task needed to keep the door assembly serviceable is contained in this single document, from initial fault isolation through composite repair and final parts ordering.

File Details

• Manual type: Component Maintenance Manual (CMM) with Illustrated Parts List
• Manufacturer: C&D Aerospace (CAGE 56135), Huntington Beach, California
• Document number: 52-51-06
• Revision: Revision 5, dated Feb 27/04
• Aircraft applicability: Boeing 737 / 757
• Language: English
• File format: PDF
• Page count: 200 pages

Chapters Covered

• Introduction – Scope; Product Support Services; Usage Guide; Abbreviations and Unit Symbols
• Description and Operation – Description; Operation; Technical Properties; Trim and Finish for 737 operators, 757 operators and Boeing production aircraft
• Testing and Fault Isolation – Mechanical Component Operational Checks for the cockpit door, pressure relief latch, deadbolt, door stop, peephole and decompression doors; Electrical Test Procedure; Fault Isolation Procedures table
• Disassembly – Cockpit Door Assembly; Pressure Relief Latch; Flight Deck Deadbolt (Harper and Skylock); Peephole Assembly; Cockpit Door Latch Assembly; Door Stop Assembly; Top and Bottom Decompression Panel Assemblies; Bonded Structure Assembly
• Cleaning – General Surface Cleaning; Metal Parts; Metal Preservation and Corrosion Inhibition; Peephole (Viewer) Cleaning; Deadbolt Maintenance; Cleaning and Lubrication of the Door Latch Assembly
• Check – visual inspection of the door knob, door stop, peephole, decorative finishes, threaded fasteners and potted inserts
• Repair – Composite Repairs; Sealing Holes in Honeycomb Panels; Filling Edge Holes in Honeycomb Panels; Aluminum Surfaces (Edge Trim/Extrusions); Replacement Procedures for BulletProof Insert (BPI), Pressure Relief Latch, aluminum trim/extrusion, Tedlar, bonded components, potted inserts and adhesive-backed placards; Viewer (Peephole) Maintenance; Threadlocker Application
• Assembly – Bonded Structure; Bottom Decompression Panel; Top Decompression Panel; Door Stop; Cockpit Door Latch; Peephole; Flight Deck Deadbolt; Low Profile Pressure Relief Latch; Cockpit Door Assembly
• Special Tools, Fixtures, Equipment and Consumables
• Illustrated Parts List – nine exploded-view figures with numerical index, equipment designator index and manufacturer CAGE code directory

From the scope statement on the first page through to the last parts-list index entry, this manual is written for the technician working on the door itself. It explains what each subassembly does, how to tell whether it is working correctly, how to strip it down and rebuild it, which adhesives and potting compounds are approved for the composite honeycomb structure, and how every part is identified for ordering. The Illustrated Parts List is broken into nine illustrated figures – the complete cockpit door assembly, the pressure relief latch, the flight deck deadbolt, the peephole assembly, the cockpit door latch assembly, the door stop assembly, the top decompression panel, the bottom decompression panel and the bonded structure assembly – each keyed to a detail parts list with part numbers, effectivity codes, indenture levels and units per assembly.

Cockpit Door Assembly Part Numbers Covered

This component maintenance manual supports the following cockpit door assembly part numbers:

• B221200-501 and B221200-503
• B221200-511 and B221200-513
• B221200-521 and B221200-523
• B221200-531 and B221200-533

Trim and finish tables are provided separately for 737 operators, 757 operators and Boeing production aircraft, indexed by customer part number codes (MA, MB, MC, MD, ME, MF, MG, MH, MJ, MK, ML, MM, MN) and by the Boeing decorative material codes DA through HD. The manual also lists the service bulletins incorporated into this revision, including B221001-52-01, B231001-52-02, B221001-52-03 and B221200-52-01, and records the temporary revisions folded into the text.

Major Subassemblies Documented

• Cockpit door assembly structure and bonded honeycomb panels
• Low profile pressure relief latch
• Flight deck deadbolt in both Harper and Skylock versions
• Peephole (viewer) assembly with objective and eyepiece lenses and Lexan plug
• Cockpit door latch assembly with crew and passenger knobs, cam, yoke, harness and latch bolt
• Door stop assembly with spring-loaded upper and lower plungers
• Top and bottom decompression panels with hinge assemblies, striker assemblies and retractable bolts
• Doorpost and partition (stub wall) mounting hardware
• Electronic Access System (EAS) interface, keypad LED indications and Door Control/Chime Module (DCM) references

Technical Properties Listed

The Technical Properties table records the door’s design data: input power of 115 VAC, 400 Hz single phase and 28 VDC; overall height 75.76 inches (192.4 cm); width 20.62 inches (52.4 cm); depth 3.50 inches (8.9 cm); and weight 75.50 lbs (34.24 kg). Door gap tolerance, deadbolt center screw torque, threadlocker cure times, potting compound work lives and cure schedules are also given in the relevant procedures.

Repair, Test and Rebuild the Cockpit Door With the Correct Procedures

Whether you are performing a scheduled inspection, chasing a door that binds or refuses to latch, replacing a damaged decompression panel, cleaning and lubricating the latch assembly, installing a potted insert into the honeycomb structure, or rebuilding the deadbolt, this manual supplies the actual procedure rather than a generic description. It tells you which threadlocker goes on the fastener, which dry lubricant goes on the latch bolt, how to torque the deadbolt center screw, how to clean the peephole without fogging the lenses, how to remove Tedlar without heat damage, and how to fill and fair a composite repair without compromising the ballistic protection behind it. On a flight deck door those details are not optional – the wrong adhesive, the wrong lubricant or an over-torqued insert can all compromise the assembly.

IMAGES PREVIEW

The C&D Aerospace B221200 Cockpit Door Assembly Component Maintenance Manual 52-51-06 is delivered as an instant-download PDF. There is no shipping, no waiting on a printed binder and no special software required – open it on a laptop, tablet or phone in the hangar, print the pages you need for the bench, and get straight into the job.