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Installation and Maintenance Instructions for Door Steward™
Contents
Installation Instructions
A. Introduction.
Insure that the intended aircraft is included in the eligibility of the STC. Installation to be accomplished by an FAA licensed Airframe Mechanic and inspected by an FAA licensed Airframe and Powerplant Mechanic with Inspection Authorization or by an FAA Part 145 Repair Station. Review all of the installation instructions before beginning the installation process. Pay particular attention to “NOTES”. Inventory the kit prior to beginning to insure it is complete. Upon completion of the installation, an FAA Form 337, Major Repair and Alteration form will need to be completed and submitted to the FAA. A sample of the completed form is included in SECTION D. For questions, comments or problems with this installation please contact Mtn View Aviation, PO Box 31, Hubbard, OR 97032, Ph. (503) 981-4550, Fax (503) 980-3366, email info@mtnviewaviation.com. Please contact Mtn View Aviation for any in service problems or difficulties with this product.
B. Description of the Product.
The Door Steward™ is a product improvement installation that greatly improves the operation of the aircraft doors. The installation consists of a gas spring attached to brackets mounted on the door and the airframe. When the door is unlatched the gas spring gently but firmly opens the door to the full open position. The gas spring while in the open position protects the aircraft and occupants from unexpected openings and closings by providing resistance to considerably higher wind gusts and prop wash than the original stops. In addition, the gas spring is extremely simple and reliable. The weight of each door installation is ˝ Lb. The original door stops can either be removed or left on the door as long as they are operating properly and not interfering with the Door Steward™. Closing the door compresses the gas spring. The gas spring can easily be removed from its brackets to facilitate removal of the aircraft door, replacement of a defective gas spring or to conduct other maintenance.
C. Tools and Equipment Requirements.
1. Screwdriver, as required for interior removal. 2. Drill Motor, #30 hi-speed drill and drill stop. 3. 1/8” Clecos and Cleco Pliers 4. Cherrymax G-27 Hand Riveter or suitable equivalent 5. Deburring tool(s) and Hand files
D. Installation Steps.
1. Refer to the Aircraft Manufacturer’s Maintenance Instructions for information regarding standard practices, precautions and notes. 2. It is the installer’s responsibility to insure that this approved installation does not interfere or conflict with any other installed equipment or options previously installed on the aircraft. 3. Remove any installed door sill covers in the area where the airframe brackets will be installed. This will be the area on the forward lower door sill where it transitions from a horizontal sill to a vertical sill. If the area has carpeting installed, it will need to be pulled back or removed. It can later be reinstalled over and around the bracket. 4. On some aircraft, the aircraft data plate may be located close to where the left hand airframe bracket mounts. The data plate may need to be relocated slightly downward. 5. Remove or loosen any interior door panels to expose the area of the door where the door bracket will be installed. On most installations where there is an interior door panel, the door bracket will be located to extend out from the door at the very bottom of the door panel, thus eliminating any need to modify the existing interior door panel. 6. Locate the airframe bracket assembly, P/N 200C101-11, LH or P/N 200C101-12, R/H onto the lower door sill and adjacent structure so that the ball stud on the bracket will be slightly higher than the intended location of the ball stud on the door bracket.
NOTE: The completed installation must have the tube end of the gas spring slightly higher than the rod end so that seal lubrication is maintained on the end seal. If the gas spring is installed level, the end seal may not maintain lubrication and could result in a gradual loss of pressure in the gas spring. (Refer to picture)
(Note the airframe attach point is slightly higher than the door attach point.)
7. If the intended location of the airframe bracket covers an existing universal head rivet in the sill seam, remove the existing rivet so the portion of the bracket that extends over the sill lays flat. It is preferable to utilize all three holes in the sill portion of the bracket, but if there is a conflict or a problem with that portion laying flat on the sill, or lying across a large radius area of the sill, insure that at least two of the three attachment holes are utilized in the sill area. 8. Using the airframe bracket as a template, locate and drill attachment holes with a #30 drill. It may be helpful to use a drill stop. 9. Debur the holes drilled in the airframe. 10 Install the airframe bracket using the provided rivets. 11. Inspect the installation for security and proper installation of the rivets. 12. If the sill had a sill cover previously removed, it will be necessary to modify it to fit back in place around this bracket. Modify as needed and reinstall any sill cover. Modify as required and reinstall any carpeting earlier removed. 13. Temporarily install the tube end of the gas spring onto the mounted airframe bracket and install the rod end onto the uninstalled door bracket, P/N 200C101-10. 14. With the gas spring fully extended and the aircraft door fully open, mark the location of the door bracket on the door. Insure it is located low enough so the bottom of the bracket will just clear the bottom of any interior door panel. 15. Remove the door bracket from the rod end of the gas spring and review the marked location. If there are interior panel attachment holes that the intended location blocks, you can either attempt to move the door bracket in toward the airframe bracket slightly or modify the bracket to allow access to the interior panel attachment hole. NOTE: If the door bracket is located toward the airframe bracket, the gas spring will try to extend the door further than the fully open position used to mark the door bracket. If you intend to retain the original aircraft door stops, this is not a problem. If using the Door Steward™ to limit the door opening, insure it will not contact or damage any other structure such as the wing strut. Also the gas spring maybe put in a bind up against the door if located too close to the airframe bracket. Double check your intended location of the door bracket while attached to the gas spring to insure none of these problems will occur. 16. If satisfied with the door bracket location, use the door bracket as a template and drill all holes with a #30 drill. Only drill through the inner door panel. It may be helpful to use a drill stop. 17. Debur the holes drilled in the door. 18. Attach the door bracket using the provided rivets. 19. Inspect the installed bracket for security and proper installation of the rivets. 20. Reinstall the interior door panel. 21. Install the tube end of the gas spring on the airframe bracket and install the rod end of the gas spring on the door bracket. Snap the locking devices down on the end fittings to securely lock the gas spring in place.
E. Post Installation Inspection and Operation.
1. Operate the door through several opening and closings to insure smooth and proper operation. Close and latch the door and inspect the interior of the aircraft. Insure the gas spring is not going to hinder or interfere with the operation of the seats, seat belts or any other feature. 2. Open the door. Insure that in the open position the gas spring does not cause the door any unintended contact with other structure. 3. Inspect that in the open position that the gas spring is not significantly hindering entry and exit from the aircraft. The gas spring should be located parallel and very close to the open door. 4. If all inspections are satisfactory, proceed to the final steps.
F. Final Steps.
1. Install the supplied Door Steward™ Equipped decal to the exterior of the aircraft near the door latch assembly of the door(s) altered. The purpose of this decal will be to provide an indication that when the door latch is opened; the door will want to push open on its own. 2. Install the following SECTION B, Maintenance, Inspection & Repair Instructions and SECTION C, Parts List, in the aircraft maintenance records. 3. Complete the FAA Form 337, Major Repair and Alteration using the included sample in SECTION D, as a guide. 4. Complete the logbook entry in accordance with CFR 14 Part 43, Maintenance, Preventive Maintenance, Rebuilding and Alteration.
Maintenance, Inspection & Repair Instructions
For questions, comments or problems with this installation please contact Mtn View Aviation, PO Box 31, Hubbard, OR 97032, Ph. (503) 981-4550, Fax (503) 980-3366, email info@mtnviewaviation.com. Please contact Mtn View Aviation for any in service problems or difficulties with this product.
ATA Chapter 05 Time Limits/Maintenance Checks
05-00 General
The Door Steward™ installation should be inspected during scheduled airframe periodic inspections that cover the door and door frame areas.
05-20 Scheduled Maintenance
Inspection of the installation will consist of the following: 1. Security of attachment of both airframe and door brackets to the associated structure. 2. Security of the gas spring attachment to the ball studs. 3. Security of the riveted ball stud to the airframe and door brackets. 4. Smooth operation of the gas spring. Inspect for evidence of end seal leakage or loss of gas spring pressure.
ATA Chapter 52 Doors
52-00 General
The Door Steward™ is a product improvement installation that greatly improves the operation of the aircraft doors. The installation consists of a gas spring attached to brackets mounted on the door and the airframe. When the door is unlatched the gas spring gently but firmly opens the door to the full open position. The gas spring while in the open position protects the aircraft and occupants from unexpected openings and closings by providing resistance to considerably higher wind gusts and prop wash than the original stops. In addition, the gas spring is extremely simple and reliable. The weight of each door installation is ˝ Lb. The original door stops can either be removed or left on the door as long as they are operating properly and not interfering with the Door Steward™. Closing the door compresses the gas spring. The gas spring can easily be removed from its brackets to facilitate removal of the aircraft door, replacement of a defective gas spring or to conduct other maintenance.
1. Removal of the gas spring from attachment ball studs
Using a #1 common screwdriver, pry up the locking devices on the end fitting approximately 5/16”. Grip the gas spring at the end fitting and pull it directly up off of the ball stud. Repeat for the opposite end.
2. Installation of the gas spring onto the attachment ball studs.
Insure the locking devices are at least 5/16” up out of the end fittings. Push the end fittings onto the ball studs. Fully depress the locking devices into the end fittings to securely lock the end fittings onto the ball studs.
3. Repair of a loose riveted ball stud in either the airframe or door bracket.
Using a Dremel or similar grinding tool remove the riveted end of the ball stud. Remove the ball stud. Inspect the bracket for security of attachment to the associated structure. Enlarge the ball stud attachment hole to 5/16” (0.3125”). Debur and slightly chamfer the hole. Install P/N 200C103-1, threaded ball stud. Install washer and self-locking nut. Torque the nut to 80 in. lbs. Inspect the installation for proper seating of the ball stud in the hole and for full engagement of the nut on the stud.
4. Defective gas spring.
A gas spring which has lost pressure is not repairable. Replace defective gas spring with a new one with the same part number as removed. Gas spring end fittings which are damaged or worn can be replaced with new. Refer to the Parts List in SECTION C for the correct part number.
Parts List for 200C10 Installation
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Dave Paradis Ph: (503) 981-4550
webpotential.com design and maintenance
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