STC Nasi PDF

National Aircraft Service Inc.
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9133 Tecumseh-Clinton Rd.
Tecumseh, MI 49286 NASI CHAPTER 1
ISSUED:
2
18 MAY 2000
DOCUMENT NAME: B727 AIRCRAFT
MAIN DECK CARGO DOOR, VENT DOOR SYSTEM,
INSTALLATION MANUAL DOCUMENT No.: PNV-727-12
DOCUMENT TABLE OF CONTENTS

DESCRIPTION PAGE
TABLE OF CONTENTS 1
DOCUMENT REVISIONS LOG 2
APPLICABILITY/APPROVALS & REQUIREMENT FOR INSTALLATION 3
GENERAL DESCRIPTION 4
RETURNING AIRCRAFT TO SERVICE 5
CHAPTER 1, INSTALLATION PREPARATION AND HARDWARE REMOVAL 6 thru 20
CHAPTER 2, MAIN CARGO DOOR LOCKING/WARNING SYSTEM INSTALLATION 21 thru 66
CHAPTER 3, VENT DOOR INSTALLATION PREPARATION AND AIRCRAFT MODIFICATIONS 67 thru 69
CHAPTER 4, VENT DOOR INSTALLATION 70 thru 74
CHAPTER 5, VENT DOOR EXTERNAL ACTUATING HANDLE ASSEMBLY INSTALLATION 75 thru 88
CHAPTER 6, CARGO DOOR GANG BAR BLOCKERS/CONTROL CABLE ASSEMBLY

INSTALLATION 89 thru 107
CHAPTER 7, HYDRAULIC SYSTEM INSTALLATION 108 thru 113
CHAPTER 8, CARGO DOOR ELECTRIC SYSTEM INSTALLATION 114 thru 131
CHAPTER 9, VENT DOOR SYSTEM OPERATIONAL TEST PROCEDURE 132 thru 137
CHAPTER 10, INSTALLATION SIGN OFF LIST 138 thru 141
APPENDIX “A”, CARGO DOOR CONTROL WIRING DIAGRAM DWG. NO. PNV-24-1703 Page 142
Appendix A
APPENDIX “B”, MCD– WARNING WIRING DIAGRAM DWG. NO. PNV-24-1575 Page 143
Appendix B
APPENDIX “C”, CARGO DOOR WIRING DIAGRAM DWG. NO. PNV-ER-0-8 Page 144
Appendix C
APPENDIX “D”, MCD– MAINT. MONITOR PANEL DWG. NO. PNV-24-2085 Page 145
Appendix D
APPENDIX “E”, “RIGGING MAIN CARGO DOOR” - PEMCO MAINTENANCE MANUAL Page 146
Appendix E
APPENDIX “F”, PACKING LIST PNV-727-PL12 Page 147
Appendix F
APPENDIX “G”, HYDRAULIC SCHEMATIC Page 148
Appendix G
REVISION: “G”
REVISION: “E”
“B” 20
17 JUL
AUGUST
NOVEMBER
2005 2004
2003
National Aircraft Service Inc. PAGE NEXT PAGE
ISSUED:
3
18 MAY 2000
APPLICABLE DOCUMENT REVISIONS
REV. DATE DESCRIPTION APPROVAL/DATE
NC INITIAL RELEASE: PAGES 1 THROUGH 124

Appendix A, B, C 18 MAY 2000
A 26 Sept 2000 Revised pages 1 thru 122 and Appendix A, B, C, D. Replace DC-8
reference figures with B-727. Added component installation sign
off sheets 26 September 2000
B 30 Dec 2003 Revised pages 1, 2, 5, 27-122

Added pages 123-127
30 December 2003
C 24 Mar 2004 Revised pages 1,2,4,7,8,10,12,14,15,16,20,22 thru 26,

28 thru 34, 36 thru 47, 49 thru 62, 67,68,69,72,73,75,76
80,81, 84 thru 127, added pages 128 thru 136
24 March 2004
D 13 May 2004 Includes all Revision C pages plus all revised pages as follows:
2, 23, 30 thru 136.
Added 137 thru 145. Added Appendix E and Appendix F. 13 May 2004
E 17 Aug 2004 Revised pages 1, 2, 7, 30, 33, 42, 43, 46, 47, 48, 49, 52, 53, 54, 56,
57, 58, 60, 61, 62, 76, 78, 79, 84, 89, 90, 108, 116, 125, 145
17 Aug 2004
F 13 Jan 2005 Revised pages 1, 2 ,23, 33, 35, 60, 61, 63, 102, 108, 120, 125, 140
and 145.
Wesley Plattner
Added page 146. Added Appendix G.
13 Jan 05
G 20 JUL 2005 Revised pages 1, 2,30, 48, 77, 78, 85 through 119, 121 through 146
and 147.
Added pages 120 and 148.. Wesley Plattner
20 Jul 05
REVISION: “C”
“B”
SEE17
24
ABOVE
NOVEMBER
MARCH 20042003
Tecumseh, MI 49286 NASI CHAPTER
ISSUED:
3 4
18 MAY 2000
APPLICABILITY /APPROVALS
This Installation Instructions Manual PNV-727-12 is applicable to Boeing Corporation aircraft

only.
Certificate by FAA per Type Certificate Data Sheet No. A3WE as follows:
All Serial Numbers as applicable to Boeing B727

aircraft listed below, modified per Pemco STC SA1444SO, SA1509SO, and
SA1543SO.
REQUIREMENT FOR INSTALLATION
Specific use of this document shall be as follows:
NATIONAL AIRCRAFT SERVICE INC. has authorized,
____________________________________________
(NAME OF AUTHORIZED PERSON OR FACILITY)
to use the data of STC No. ST01270CH issued on 07 July 2000,
to modify Boeing B727 aircraft model ________________,
Serial Number ____________________
All proprietary rights are reserved
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2000 2003
ISSUED:
5
18 MAY 2000
GENERAL DESCRIPTION
1.1
The NASI Vent Door Safety System installation must be performed by a licensed Airframe Mechanic
or repair person under the direct supervision of an FAA or CAA Licensed Airframe Mechanic, or Certi-
fied Repair Agency. Entities performing the work shall be proficient in sheet metal, electrical and me-
chanical abilities as per standard aeronautical practices, procedures and mandates. In the event that any
area(s) where this installation is to take place shows physical damage or pre-existing repairs that will
impinge with this installation sequences, personnel should refer to the applicable manufacturer mainte-
nance, structural repair, or overhaul manual/s and or local governing aeronautical agencies, i.e. FAA,
CAA and/or NASI to assure the aircraft is in an airworthy condition to host this vent door safety sys-
tem.
1.2
Aircraft standard practices and applicable sections of FAA Advisory Circular AC43.13-1B applies to
this installation. Therefore, detailed information relative to fastener length, torque, elongated holes,
edge distance and corrosion prevention may be omitted in places in this instruction.
1.3
It is mandatory that the modification area be inspected by qualified and certified personnel for struc-
tural integrity and airworthiness. The structure must be determined to be in compliance with applicable
A.D. Bulletins, Service Bulletins and Documents applicable to Boeing Model B727 aircraft.
1.4
For any deviation whatsoever from installation instructions contained herein, or from approved current
standard aircraft maintenance practices, manufacturers recommendations and or other applicable guide-
lines, notify in writing for re-evaluation to the local FAA-FSDO, CAA and/or National Aircraft Service, Inc.
1.5
Any approved deviated work schemes for this installation shall be included in the traceable aircraft
maintenance records file.
1.6
The accountability block located in the lower right hand corner of certain pages for each section of
installation steps, must by signed and dated by the person performing the task(s).
1.7
Parts/Drawing List:
(a) Reference Vent Door System Packing List PNV-727-PL12.
NOTE: This mod includes rigging inspections. Parts found unairworthy during inspections are not part of
this kit.
READ THIS PAGE 4, ACKNOWLEDGE: DATE:
REVISION: “C”
“B” 24
17 MARCH
NOVEMBER
2004 2003
ISSUED:
6
18 MAY 2000
9.1 RETURNING AIRCRAFT TO SERVICE
After the installation is complete the following MUST BE ACCOMPLISHED:
(1) Assure that the completed installation agrees with this instructions manual and all items on the
installation sign off sheet (located at the end of this manual) are signed off.
(2) Assure that all workmanship is satisfactory and complies with approved standard procedures.
(3) Assure that all tools and/or left-over materials used for the installation are removed from the
aircraft interior. All areas must be swept clean from foreign objects and debris.
(4) Determine by functional operation that the NASI vent door system operates properly.
Ref. Chapter 9 Vent Door system operational test procedure.
(5) Necessary paperwork related to the aircraft records must be completed as noted on the
following lines 6 thru 8.
(6) Process FAA Form 337 and/or approved airline maintenance entries and release.
(7) Transcribe applicable entry in the aircraft log look.
(8) To the Weight and Balance Record, make the following revision:
(a) B727: Add 47.0 pounds at fuselage station 568.8 (-200) & 548.8 (-100)
(9) Include the latest revised copy of document PNV-727-12, PNV12-MM, AFM and MEL in the
operators publications loop for circulation and use.
(10) Circled numbers (Find Numbers) on all figures will be initially addressed as a “˜ ”. As these
Find Numbers are being repeated in each section throughout this document, they will then be
addressed as “(FN X)”.
(11) Aircraft standard practices and applicable sections of the FAA Advisory Circular AC43.13-
1B & 2A apply to this installation. Some fasteners may differ from figure pictures shown on
this document or from original aircraft manufacturer designation.
READ THIS PAGE 5, ACKNOWLEDGE: DATE:
REVISION: “B” 30
17 DECEMBER
NOVEMBER 2003
Tecumseh, MI 49286 NASI CHAPTER 1 6
ISSUED:
7
18 MAY 2000
CHAPTER 1
INSTALLATION PREPARATION
AND HARDWARE REMOVAL
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
7 8
18 MAY 2000
9.2 EXISTING HARDWARE REMOVAL

In order to accomplish the NASI Vent Door and Locking/Warning Systems Installations, some of the
aircraft’s existing hardware, mechanical and electrical must be removed. (The existing lock rod, lock
rod actuator and lock rod switches are to be removed with associated hardware.)
1) Remove existing shields covering torque tube. (Retain all hardware for re-install)
2) Remove the existing hydraulic lock rod cylinder from the cargo door, located at STA 550.
(Fig. 1-5)
a) Disconnect and cap hydraulic lines as needed. (Ref. Hydraulic schematic Fig. 1-8).
3) Remove the existing micro-switch and mounting plate adjacent to each latch assembly. Discard
parts noted on Figure 1-6.
4) Remove AFT lock rod switch located at STA 650 (-200) or STA 630 (-100), WL 210.
(Fig. 1-3)
5) Remove switch S18 at STA 530 (-200) or STA 510 (-100), WL 210. (Fig. 1-4)
6) Remove FWD lock rod switch S2A located at STA 512 (-200) or STA 492 (-100), WL 210.
(Fig. 1-2)
7) Remove lock pin view window. Replace with PNV13-5-11 using existing type fasteners.
(Fig. 1-7 & §9.2.1)
8) Remove lock bar plates and remove lock bar. (Fig. 1-5)
a) Lock bar may be cut through as required to facilitate removal.
NOTE: All disconnected wiring which is

not removed must be capped and stowed.
REMOVE TORQUE
TUBE SHIELDS
REMOVE
LOCK BAR
THROUGH THIS
FIGURE 1 ACCESS HOLE
TORQUE TUBE SHIELDS
REMOVAL
REVISION: “E”
“B” 17 AUGUST
NOVEMBER
2004
2003
ISSUED:
9
18 MAY 2000
EXISTING HARDWARE REMOVAL
Ref: Fig. 1-2
FIGURE/ PART NUMBER NOMENCLATURE DISPOSITION UNITS

ITEM PER
ASSY
1-2 MICRO SWITCH REMOVAL-LOCK ROD
10 602EN602-6 MICRO SWITCH (S2A) (V91929) DISCARD 1
15 29-894-11 BRACKET (V91763) ATTACHING PARTS DISCARD 1
20 NAS517-3-4 SCREW DISCARD 3
25 AN960-10L WASHER DISCARD 3
30 MS21042-3 NUT DISCARD 3
REVISION: “C”
“B” 17
24 NOVEMBER
MARCH 20042003
ISSUED:
10
18 MAY 2000
20
A 25
30 15
A
10
FIGURE 1-2
CYLINDER/MICRO-SWITCH
REMOVAL
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
10 11
18 MAY 2000
Ref: Fig. 1-3

ITEM PER
ASSY
10 602EN602-6 MICRO SWITCH (S17) (V91929) DISCARD 1
REVISION: “C”
“A”
“B” 24
17
26 MARCH
NOVEMBER
SEPT 2003
2004 2003
ISSUED:
12
18 MAY 2000
A
20
15 25
30
10
FIGURE 1-3
MICRO-SWITCH REMOVAL
LOCK ROD
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
13
18 MAY 2000
Ref: Fig. 1-4

ITEM PER
ASSY
10 602EN602-6 MICRO SWITCH (S17) (V91929) DISCARD 1
35 29-894-19 PLATE ASSY-STRIKER (V91763) DISCARD 1
REVISION: “C”
“A”
“B” 24
17
26 MARCH
NOVEMBER
SEPT 2003
2004 2003
ISSUED:
14
18 MAY 2000
A A
15
10 20
25
30
35
40
45
50
FIGURE 1-4
MICRO-SWITCH REMOVAL
LOCK ROD
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
14 15
18 MAY 2000
Ref: Fig. 1-5

ITEM PER
ASSY
1-5 LATCH-SAFETY CYLINDER REMOVAL
10 52-779-1 CYLINDER (A1) (V91763) DISCARD 1
15 MS20592-3R29 PIN DISCARD 2
20 MS24665-170 PIN COTTER DISCARD 2
30 358677 MOUNT PIVOT (V05448) DISCARD 1
55 52-702-30 LOCK ROD PLATE DISCARD 1
60 52-702-5 LOCK ROD ASSEMBLY DISCARD 1
REVISION: “C”
“B” 24
17 MARCH
NOVEMBER
2004 2003
ISSUED:
16
18 MAY 2000
15
30
10
15
55
20
20
60
A
FIGURE 1-5
CYLINDER REMOVAL
LATCH-SAFETY
REVISION: “C”
“B” 17
24 NOVEMBER
MARCH 20042003
ISSUED:
17
18 MAY 2000
Ref: Fig. 1-6

ITEM PER
ASSY
1-6 SWITCH REMOVAL-OVER-CENTER INDICATING
LIGHT
10 52-798-2 BRACKET (V91763) DISCARD 1
15 MS27240-1 MICRO SWITCH (S6 THRU S12) DISCARD 1
20 52-798-10 ANGLE (V91763) ATTACHING PARTS DISCARD 1
30 NAS1149F0332P WASHER DISCARD 2
40 MS20470D6-8 RIVET DISCARD 2
45 MS20995C20 WIRE-SAFETY (NOT SHOWN ON FIGURE 1-6) DISCARD AR
—————————– * ——————————–
50 52-798-8 BRACKET-CAM (V91763) DISCARD 1
REVISION: “C”
“B” 17
24 NOVEMBER
MARCH 20032003
ISSUED:
18
18 MAY 2000
A
A 10
15
20
40
25
30
50
35
FIGURE 1-6
SWITCH REMOVAL
OVER-CENTER INDICATING LIMIT
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
18 19
18 MAY 2000
Ref: Fig. 1-7

ITEM PER
ASSY
1-7 WINDOW REMOVAL-LOCK ROD CHECK
10 52-754-2 PANE WINDOW (V91763) DISCARD 1
9.2.1
1) Remove existing window by drilling out rivets. Assure no damage to existing back-plate, and save
plate, (it will be re-used later).
2) Discard existing rubber seal and window.
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
20
18 MAY 2000
10
FIGURE 1-7
ROD CHECK WINDOW REMOVAL
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
20 21
18 MAY 2000

FIGURE/ PART NUMBER NOMENCLATURE DISPOSITION UNITS PER
ITEM ASSY
1-8 CYLINDER-LINE REMOVAL
10 HYDRAULIC LINE DISCARD 1
20 HYDRAULIC LINE DISCARD 1
30 (52-779-1) HYDRAULIC CYLINDER PREVIOUSLY REMOVED (1)
40 AN820-4 CAP INSTALL 2
UP
40
AFT
30 (REF)
CARGO DOOR 10 40
20
FIGURE 1-8
CYLINDER-LINES REMOVAL
REVISION: “C”
“B” 17
24 NOVEMBER
MARCH 20042003
ISSUED:
22
18 MAY 2000
CHAPTER 2
MAIN CARGO DOOR

LOCKING/WARNING SYSTEM
INSTALLATION
REVISION: “A”
“B” 17
26 NOVEMBER
SEPT 2003 2003
ISSUED:
23
18 MAY 2000
9.2.2 Latch Assembly Removal

Remove each of the seven (7) assemblies as follows: (Fig. 2)
NOTE: CARGO DOOR MUST BE BRACED OPEN AT LEAST 4 INCHES WITH LATCHES
CLOSED AND LATCHED. MARK EACH LATCH ASSEMBLY WITH A TAG WITH A
NUMBERING SYSTEM ONE THRU SEVEN FROM FRONT TO BACK. ASSURE THE
ASSEMBLIES WILL BE REPLACED AT THE SAME LOCATION FROM WHICH
THEY WERE REMOVED. LATCHES WILL BE RE-USED. IT IS CRITICAL FOR RIG-
GING THAT LATCHES BE KEPT WITH THE SAME HARDWARE AND SHIMS THAT
THEY CAME WITH FOR THE NEXT STEPS ON THE FOLLOWING PAGES.
(1) Remove four existing bolts. (FN 2)
(2) Remove two existing counter sink Phillips head screws. (FN 4)
(3) Detach existing link assembly (FN 3) from latch assembly attached to torque tube.
Do not loosen any jam nuts on linkage or rod ends. (Figure A)
FIGURE A
(4) Any shims behind the latch assembly base MUST BE KEPT WITH EACH LATCH
ASSEMBLY AS A SET. It is recommended that two upper bolts be used to keep each shim or
shims at each latch assembly location. Damage to these shims must be avoided whenever
possible, any damaged shims will have to be re-fabricated with an aluminum shim of the
same thickness.
(5) Clean and degrease each latch assembly once removed from the door.
REVISION: “C”
“B” 24
17 MARCH
NOVEMBER
2004 2003
ISSUED:
24
18 MAY 2000
(FN 5)
(FN 3)
(FN 2)
(FN 1)
(FN 4)
FIGURE 2 FWD
(Looking outboard)
Find No. Description Disposition
1 Existing latch assembly (typ.) Rework per § 9.3.2
2 Existing bolts, (4 ea.) Reuse
3 Existing link assembly Reuse
4 Existing Phillips head counter sink screws, (2 ea.) Reuse
5 NAS464P4-12 bolt, AN960-416 washer and AN320- Install New

4 nut (REF)
NOTE: SHIM(S) MAY BE ENCOUNTERED BEHIND EACH BASE, SEE § 9.2.2 (4).
REVISION: “B”
“F” 13
17JANUARY
NOVEMBER
2005
2003
ISSUED:
25
18 MAY 2000
9.2.3 Latch Disassembly (Applies to all seven Latch Assemblies)

Disassemble latch assembly as follows: (Fig. 3, 3-1 and 3-2)
NOTE: SOME PARTS WILL BE REPLACED WITH NASI KIT PARTS AT TIME OF
RE-ASSEMBLY.
(1) Remove bolt, washer, nut, and cotter pin (FN 1) from connecting link (FN 2) to the hook
sub-assembly (FN 10). Do not remove the hook from the base.
(2) Swing link (FN 2) outwards and remove inner bushing. (FN 9)
(3) Remove bolt, washer, nut, and cotter pin (FN 5), lever assembly (FN 4) and link (FN 2)
should be free to rotate out at this time.
(4) Remove bolt, washer, nut, and cotter pin (FN 7) (Fig. 3-1)
NOTE: This bolt fastens the cam (FN 8) to the base. (FN 6) (Fig. 3-1 and 3-2)
(5) Remove bolt, washers, nut, and cotter pin (FN 3) attaching the link (FN 2) to lever
assembly (FN 4), remove link (FN 2) and bushing (FN 9) see picture insert. (Fig. 3-2)
(6) Degrease and clean all parts thoroughly.
REVISION: “C”
“B” 24
17 MARCH
NOVEMBER
2004 2003
ISSUED:
25 26
18 MAY 2000
DOOR LATCH DISASSEMBLY
1 Existing bolt, washers, nut & cotter pin Reuse nut, bolt and washer
2 Existing 2361130 link sub-assembly Reuse all
3 Existing bolt*, washers, nut & cotter pin Reuse nut
4 Existing 4773462-1 lever sub-assembly Discard
5 Existing bolt, washer, nut & cotter pin Reuse nut, bolt and washer
6 Latch Assembly Base 37727941 Reuse
7 Existing bolt, washer, nut, cotter pin Reuse nut, bolt and washer
8 Existing 2363572 cam Reuse, see 9.3.2(9)(a)
9 Existing NAS72-7-010 bushings Reuse
10 Existing 3773874-1 Hook Sub Assembly Reuse
REVISION: “C”
“B” 24
17 MARCH
NOVEMBER
2004 2003
ISSUED:
27
18 MAY 2000
LATCH TO
TORQUE TUBE
DOOR LATCH DISASSEMBLY
LINK ASSY
(FN 4)
(FN 7)
(FN 5)
(FN 3)
(FN 2)
FIGURE 3-1
Right side view
(FN 1)
(FN 6) (EACH CAM MUST BE
KEPT WITH LATCH AS
(FN 10) A SET) (FN 8)
(FN 3)
FIGURE 3
Left side view
(FN 4)
(FN 2)
link
Sub-Assy
(FN 9)
FIGURE 3-2
Removed Details
REVISION: “C”
“B” 17
24 NOVEMBER
MARCH 20042003
ISSUED:
27 28
18 MAY 2000
9.2.4 Modify Latch Base (Applies to all eight latch assemblies)

1. Rework lock pin hole as illustrated in Fig. 3-3 prior to re-assembly § 9.3.2
NOTE: Rework required as illustrated.
Latch Base (REF)

Existing .4375 diameter
lock pin hole.
Enlarge to .5024
.5016 diameter
near side only.
FIGURE 3-3
17 DECEMBER
NOVEMBER 2003
ISSUED:
29
18 MAY 2000
9.3.1. Assembly and installation of cargo door view window plug

Prepare for assembly and install cargo door view window plug. Ref. Fig. 3-4
(1) Replace existing window {removed in Chapter One Fig. 1-7}
(2) Using existing view window back-up plate {removed in Chapter One Fig. 1-7}, #21 transfer drill
hole pattern into new window plate (FN 1).
(3) Using clecos, secure window plate (FN 1) into position (in place of removed window back-up
plate). .
(4) Place plug (FN 2) into position of removed view window, against window plate (FN 1). #21 back
drill window plate (FN 1) from plug (FN 2).
(5) Rivet plug (FN 1) to window plate (FN 2). Use rivets (FN 3). Install wet with sealant CS3204-
B1/2 or equivalent.
(6) Remove window plug assembly. Clean and debur if needed.
(7) Apply faying seal of CS3204-B1/2 or equivalent to new window plug assembly and install on
door skin using MS20426AD(x)-(x) rivets as required
(Continued on next page)
REVISION: “C”
“B” 29
17
24 DECEMBER
NOVEMBER
MARCH 20042003
ISSUED:
29 30
18 MAY 2000
9.3.1 Assembly and installation of cargo door view window plug.
CARGO DOOR
FIGURE 3-4
FIND NO. DESCRIPTION
1 PNV13-5-3 PLATE
2 PNV13-5-1 PLUG
3 MS20426AD5-7 RIVETS (4 ea.)
REVISION: “C”
“B” 29
17
24 DECEMBER
NOVEMBER
MARCH 20042003
ISSUED:
31
18 MAY 2000
9.3.2 Latch Re-Assembly (Applies to all seven latch assemblies)

With all parts de-greased and clean, the latch will be re-assembled with some new parts as follows:
Fig. 4, 4-1a, b, c, 4-2a, b, c, 4-3 and 4-4a, b and 4-5.
(1) Insert bushing (FN 5) into link (FN 4).

NOTE: The end of the link (FN 4) with shorter distance from the stop protrusion to the hole
must be installed in the new NASI lever. (FN 1)
(2) Insert link (FN 4) with installed bushing into the NASI new lever (FN 1). Insert NASI
special bolt. (FN 3) Make sure that the bolt head sinks into the provided counter bored hole.
Install with washer (FN 6), nut (FN 8) and cotter pin. (FN 7) This link sub-assembly should
look just as shown on Fig. 4-1c.
(3) Holding the link sub-assembly with washer (FN 2) and the cam (FN 9) in place, (Fig. 4-1c),
slide the assembly into the latch base, as it is shown on Fig. 4-2a, b, c.
NOTE: Use additional washers (FN 25) or (FN 28) as required. Ref. steps 4 and 5.
(4) Assemble LATCH #3 and LATCH #5 with a bolt (FN 27), a washer (FN 28), a bracket
(FN 10), three washers (FN 25), a tab (FN 26), existing nut (FN 15) and a cotter pin.
(FN 16) {Fig. 4-3}
(5) Assemble LATCHES #1, #2, #4, #6, and #7 with a bolt (FN 13), a bracket (FN 10), a exist-
ing washer (FN 14), existing nut (FN 15) and a new cotter pin. (FN 16) {Fig. 4-3}
(6) Remove the grease fitting from the old lever assembly and replace it into the new lever as
shown on Fig. 4-3 picture insert.
(7) Install the second existing bushing (FN 5) into the link (FN 4) and slide the link into the
latch hook (Fig. 4-3) Install bolt (FN 23) with existing washers {FN 22 & 17}, thread the
nut (FN 18) and install a new cotter pin. (FN 19) Re-lubricate the two fittings with approved
aircraft grease.
(8) Remove 1/4” bolts (or rivets) from aft frame behind each of all seven latches. (Fig. 4-4)
(9) Counter sink holes from removed 1/4” bolts (or rivets) and install screws (FN 29) washers
(FN 30), and nuts. (FN 31) (14 plc.) {Fig. 4-4}
REVISION: “B”
“G” 17
20 NOVEMBER
JUL 2005 2003
ISSUED:
31 32
18 MAY 2000
9.3.2 Latch Re-Assembly (Applies to all seven latch assemblies)

(10) Templates
(a) Place template (FN 32) on aft three latch mount bolt holes of latch position #1 and 9/16 drill
from template thru cargo door inner skin. Repeat procedure on latch position #6 {Fig. 4-5}.
(9/16 drilled hole for wiring to switches S1 and S2 when blockers are installed in chapter 6)
(b) Refer to Fig. 10-5 “Template Layout.” Place templates (FN 70-80, FN 82-52, FN 100) as
illustrated on cargo door and frame and drill through using #40 size drill unless larger size is
indicated by hole in template.
REVISION: “B”
“D” 23
17
13 DECEMBER
NOVEMBER
MAY 2004 2003
ISSUED:
33
18 MAY 2000
DOOR LATCH RE-ASSEMBLY

1 NASI PNV17-1-1 lever sub-assembly (7 ea.) New
2 PNV17-1-4 washer New
3 NASI PNV18-1-1 special bolt (7 ea.) New
4 Existing 2361130 link sub-assembly* Reuse
5 Existing NAS72-7-010 bushings, (2 ea.) Reuse
6 Existing AN960-716 washer Reuse
7 AN381-3-12 cotter pin (7 ea.) New
8 Existing AN320-7 nut Reuse
9 Replacement Z-52-3004 cam (NOT IN KIT) Use existing unless worn
beyond limit. Ref (9) and (9)(a)
10 NASI PNV03-3-5 bracket (7 ea.) New
11 Existing NAS1104-6D bolt Reuse
12 New MS24665-132 cotter pin (7 ea.) New
13 NAS464P8-59 bolt, (5 ea.†) New
16 MS24665-132 cotter pin (7 ea.) New
17 Existing AN960-716 Washer Reuse
18 Existing AN320-7 Nut Reuse
19 AN381-3-12 Cotter pin (7 ea.) New
20 Existing base Reuse
21 Existing hook Reuse
22 Existing AN960-716 Washer Reuse
23 Existing bolt Reuse
* NOTE THAT DISTANCE FROM RIGHT HOLE C/L TO STOP TAIL C/L IS SHORTER THAN FROM LEFT HOLE C/L
READ STEP (1) §9.3.1.
† USED ON FIVE LATCH ASSEMBLIES Nos. 1, 2, 4, 6 and 7 only.
REVISION: “B”
“D” 23
17
13 DECEMBER
NOVEMBER
MAY 2004 2003
ISSUED:
34
18 MAY 2000

24 NASI furnished .9338 diameter gauge bar New (use for rigging)
25 AN960-816 washer, (3 ea., 2 pl.) ‡ New
26 PNV03-9-5 spring tab, (2 ea.)‡ New
27 NAS464P8-64 (-61 alternate) Bolt, (2 ea.)‡ New
28 AN960C-816L washer (7 ea.) New
29 NAS517-4-5 screw, (14 ea.) New
30 AN960-416 washer, (14 ea.) New
31 MS21042-4 nut, (14 ea.) New
32 PNV21-0-47 Template New (use for hole location)
35 NAS464P4-12 bolt (7 ea.) New
36 AN960-416 washer (7 ea.) New
37 AN320-4 nut (7 ea.) New
‡ USED ON TWO LATCH ASSEMBLIES #3 AND #5.
REVISION: “B”
“F” 13
17 JANUARY
23 NOVEMBER
DECEMBER2005
2003
ISSUED:
35
18 MAY 2000
(FN 2)
10
3
(FN 9)
(FN 4)
(FN 8)
(FN 6) 7
STOP (FN 5) FIGURE 4
NEW AND RE– USED
PARTS
NOTE THAT DISTANCE FROM RIGHT HOLE C/L TO STOP TAIL C/L IS SHORTER THAN ROM LEFT HOLE C/L
READ STEP (1) IN PAGE 13.
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
35 36
18 MAY 2000
CAM (FN 9)
(FN 1)
FIGURE 4-1
Lever sub-assembly (FN 35)
(FN 4)
(FN 7)
(FN 6)
(FN 8)
(FN 3)
(FN 9)
(FN 1)
(FN 2)
(FN 35)
(FN 37) (FN 36)
REVISION: “B”
“F” 13
17 JANUARY
30 NOVEMBER
DECEMBER2005
2003
ISSUED:
37
18 MAY 2000

(FN 4)
(FN 4) (FN 1) (FN 9) (FN 1)
FIGURE 4-2a 12 33 34 (FN 2) FIGURE 4-2b

(FN 3)
FIGURE 4-2c
(FN 11)
FIGURES 4-2a thru 4-2c

Lever sub-assembly
Difficult Step Views
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
38
18 MAY 2000
27 ‡
28 ‡ REMOVE GREASE
FITTING AND REPLACE
HERE
26 ‡
25 3X ‡
16
(FN 13)
OR
(FN 27)
(FN 15) †
(FN 14) †
13 †
(FN 10)
(FN 17)
(FN 18)
(FN 23)
19 (FN 22)
(FN 20)
(FN 21) FIGURE 4-3

Left and Right side
Views
‡ USED ON TWO LATCH ASSEMBLIES, Nos. 3 AND 5 only.
† USED ON FIVE LATCH ASSEMBLIES Nos. 1, 2, 4, 6 and 7.
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
39
18 MAY 2000

FIGURE 4-4
FASTENERS
REPLACEMENT
( AT ALL 7 LATCH
POSITIONS, REMOVE 1/4”
BOLTS OR RIVETS AND
INSTALL THE
FOLLOWING:)
29
7X 30
31
FIGURE 4-5
9/16” Drill (FN 32) FS 489.21 (Latch Position #1)

Hole FS 600.00 (Latch Position #6)
REVISION: “C”
“B”
“D” 24
17
13MARCH
NOVEMBER
MAY 2004
2004 2003
ISSUED:
40
18 MAY 2000
9.3.3 Test Latch Overcenter Closing Force

(1) Install the NASI-supplied .9338 in. diameter gauge (FN 24) between hook (FN 21) and base
(FN 20). Ref. Fig. 5-1
(FN 21)
(FN 20)
24
FIGURE 5-1
Adjusting Over Center
Tension Using Gage
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
41
18 MAY 2000

(2) Using spring scale, test overcenter closing load. Ref. Fig. 5-2
SCALE LEVER (FN 1)
25 TO 35 LBS. BOLT
SNAP OVER CENTER FIGURE 5-2
Latch Assembly Tension
Adjustment
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
42
18 MAY 2000

(3) If 25-35 lbs overcenter closing force is not obtained, cam (FN 9) adjustment is required as
follows:
a) Remove bolt (FN 11) and nut (FN 12).
b) Rotate cam, clamp in place and retest closing force until 25-35 is obtained.
CAUTION: ASSURE CAM (FN 9) IS SECURELY CLAMPED IN PLACE BEFORE

DRILLING NEW HOLE IN FLANGE. IF CAM (FN 9) SLIPS WHILE DRILLING,
THE CAM (FN 9) WILL BE DESTROYED. RETESTING OVERCENTER FORCE
TWO TO THREE TIMES BEFORE DRILLING IS SUGGESTED.
FIGURE 5-3
Drilling Cam
SCALE ARM
25 TO 35 LBS. BOLT
SNAP OVER CENTER FIGURE 5-4
Latch Assembly Tension
Retesting
REVISION: “B”
“D” 17
13 NOVEMBER
MAY 2004 2003
ISSUED:
43
18 MAY 2000

(4) Adjust cam (FN 9) to obtain 25-35 pounds closing load at arm of lever (FN 1).
{Fig. 5-5 and 5-6}
a) After cam adjustment, if holes for bolt (FN 11) in cam (FN 9) and base (FN 20) do
not align, a new hole may have to be drilled thru flange in cam. Select hole in base
(FN 20) to drill thru. A minimum 1½ “D” from existing hole is needed for new
location of hole.
(5) Install bolt (FN 11), existing washer (AN960-416L), existing nut (AN320-4) and new cotter
pin. (FN 12)
(FN 9)
Figure “8”
condition
not accept-
able
11/2 “D”
FIGURES 5-5 FIGURES 5-6
(6) Lever must clear base (FN 20) while in locked position, with lever (FN 1) over-center and
against stop on link. (FN 4) {Fig 5-7}
ALLOW FIGURE 5-7

GAP Latch Assembly Tension
.003 INCH Adjustment Gap
MIN.
REVISION: “E”
“B” 17 AUGUST
NOVEMBER
2004
2003
ISSUED:
43 44
18 MAY 2000

(7) Re-install the existing link that connects to the torque tube to the new lever behind the latch
assembly. Use NAS464P4-12 bolts, existing AN960-416L washer, AN320-4 nut and
MS24665-132 cotter pin.
NOTE: Do not make linkage adjustments at this time.
(8) At this point re-attach each latch assembly. Use each assigned location with the same shim/s
originally found between the base and the aircraft inner skin with the existing four (4) bolts
and two (2) Phillips head screws. (Removed in §9.2.2). These fasteners should be tightened
with only force required to pull latch snug with the door. Latches may require removal for
adjusting rod rigging in 9.3.3
REVISION: “E”
“B” 17 AUGUST
NOVEMBER
2004
2003
ISSUED:
44 45
18 MAY 2000
9.3.3.1 Latch Adjustment Procedure (Applies to all seven Latch Assemblies)

Adjust each latch and then re-adjust if needed, proceed as follows:
NOTE: Latch must be removed for adjusting rod adjustments and reinstalled to check rigging for each
adjustment.
(1) Using a socket and a breaker bar (on the manual unlock bolt installed in the forward end of
the torque tube) manually rotate the torque tube assembly up into their latched (latch over
center) position.
(2) Using the .003-inch (NASI supplied) feeler gauge (FN 1) insert behind the existing latch as-
sembly link. (FN 3) {Fig. 5} Locate the latch (closer to the center of the door) that the feeler
gauge will not fit through, this will be the “base latch” for adjustment.
(3) Slide a lock pin into the “base latch” and shorten all other six link adjusting rods to allow
the .003-inch feeler gauge to fit past the latch link stop.
(4) Slide lock pins into each of the six latches and re-check the “base latch” for no clearance and
the other six latches for .003-inch clearance.
(5) The .003-inch clearance should be tight or snug on the feeler gauge. The adjusting rod is
lengthened until the .003-inch feeler gage is tight and shortened slightly until the feeler gage
can be pulled free. The “base latch” must always be against the link stop with no clearance.
(6) Remove the lock pins and manually un-latch and latch over center the latches with a 200 ft./
lb. (min) torque wrench. The maximum allowable torque is 180 ft./lb. If torque required is
over 180 ft/.lb. refer to the Boeing 727 maintenance manual for latch and spool shimming
and alignment.
(7) Tighten all 14 jam nuts on the 7 latch adjustment rods and inspect all witness holes for proper
thread engagement.
(8) Re-install all 7 lock pins and verify clearance fit is loose with absolutely no binding allowed.
Any tight lock pins will require repeating these 8 steps.
NOTE: Check torque of latch attach bolts.
(9) Verify all bolts securing latches to door are tightened properly
REVISION: “B”
“D” 17
13 NOVEMBER
MAY 2004 2003
ISSUED:
46
18 MAY 2000
LATCH ASSEMBLY “LATCH-OVER-CENTER ADJUSTMENT
(FN 2)
(FN 3) 1
(FN 4)
FIGURE 5-8
7 Pl. Typ.

1 Provided .003-inch thick feeler gage Tool for rigging
2 Existing latch to torque tube link assembly (typ.) Reference
3 Existing latch assembly link Reference
4 New lever PNV17-1-1 Reference
REVISION: “B”
“D” 17
13 NOVEMBER
MAY 2004 2003
ISSUED:
46 47
18 MAY 2000
9.3.4 New Gang-Bar/Swivel Arm Replacement and Cylinder Installation.

Install the new hydraulic cylinder, gang-bar, swivel arms and lock pins as follows: {Fig. 6 thru 6-11}
(1) Use lexan transfer drilling template (FN 50) to locate and transfer drill bolt holes in bracket (FN 1). Use
#11 drill bit. (Ref. Fig. 6)
(2) DELETED
NOTE: DELETED
(3) DELETED
a) DELETED
NOTE: DELETED
(4) DELETED
(5) DELETED
(6) DELETED
(7) DELETED
(8) DELETED
(9) Install lock blocks (FN 53), use bolts (FN 54), washers (FN 55) and nuts (FN 56).{Ref Fig. 6-11}
NOTE: The following steps (10), (11) & (12) are applicable to TYPE I & TYPE II doors only.
(10)Mark latch position number and “FWD” on the forward end of the torque tube cover channels located aft
of latch positions 2 through 6, and remove these channels by drilling the MS20470AD5 rivets (3 pl ea.).
{Ref Fig. 6-6}
(11)Place swivel arm cutout template (FN 57) on channel with cutout forward. Mark and cut out notch for
swivel arm {Ref Fig. 6-7}
(12) Reinstall torque tube cover channels with MS20470AD5 rivets (3 pl ea.) {Ref Fig. 6-6 & 6-7}
REVISION: “C”
“E”
“B” 17
24 AUGUST
NOVEMBER
MARCH 2004
2004
2003
ISSUED:
47 48
18 MAY 2000
9.3.4 New Gang-Bar/Swivel Arm Replacement and Installation.
(13)Install swivel arms with lock pins (FN 17) to support brackets (FN 1) using bolt (FN 19), washer (FN 20)
2 pl., washer (FN 21) 2 pl., nut (FN 22) and cotter pin (FN 23) at each of the seven locations {Ref Fig. 6-
8}.
NOTE: Gang bar must be in locked position for next step (14).
(14) Insert the bushing (FN 14) into 1/4” dia. Hole on the inbd side of the gang bar, thru the swivel arm (FN
17) and thru the 1/4” dia. hole in the outbd side of the gang-bar (All seven latch positions). (Slight force
may be required)
CAUTION: ALL BOLTS ATTACHING THE SWIVEL ARMS TO THE GANG-BAR MUST BE
INSTALLED WITH THE HEX HEADS INBOARD AND NUTS OUTBOARD. THIS IS IMPORTANT!
(15) Install the bolt (FN 13) , washer (FN 12) 2 pl., nut (FN 16) and cotter pin. (FN 15) 7 pl ea. {Ref Fig. 6-
8}.
(16) Install the secondary springs (FN 18) at all seven latch assemblies locations. {Ref Fig. 6-8} (attachment
ends of springs must be sprung slightly open for installation and sprung back with small needle-nosed
pliers {Ref Fig. 6-8})
(17) Install attachment for each of the two master springs (FN 24) at latch 3 and 5. {Ref Fig. 6-10}.
(18) Install spacer (FN 44) and tab (FN 45) 2 pl. ea., use bolts (FN 46), washers (FN 42) and nuts (FN 43)
{Ref Fig. 6-10}.
(19) Install master springs (FN 24) at latch 3 and latch 5 {Ref Fig. 6-10}.
(20) Place template (FN 52) over forward torque tube guard, trace a 3.00 by 3.00 inch cut out for hydraulic
lines. Drill 1/4” holes at all four corners of cut out. Use sheet metal shears or saw and cut hole pattern
{Ref Fig. 6-13}.
(21) Install hydraulic cylinder (FN 35) using bolt (FN 28), washer (FN 29) 2 ea., nut (FN 30) and cotter pin
(FN 31). {Ref Fig. 6-12}.
(22) Install hydraulic cylinder’s clevis (FN 40) and nut (FN 41) may require adjustment. {Fig. 6-12}.
a) With gang bar in fully locked position, pull hydraulic cylinder rod with clevis to fully extended
position. When installing bolt (FN 36), gang bar must remain fully locked.
(23) Install cylinder assembly to gang bar (FN 11) with bolt (FN 36), washer (FN 37) 6 ea., nut (FN 38)
and cotter pin (FN 39). {Fig. 6-12}. Bolt (FN 36) must rotate freely with fingers with no preload between
hydraulic cylinder and gang bar.
(24) Hydraulic lines installed in Chapter 7.
(25) Place template (FN 59) over upper forward torque tube guard and trace outline of cut out (for hydraulic
lines). Drill 1/4” holes at all three inside corners of cut out. Use sheet metal shears or a saw and cut per
pattern. {Ref Fig. 6-13}.
REVISION: “C”
“E”
“B” 17
23
24 AUGUST
NOVEMBER
DECEMBER
MARCH 2004
2004
2003
ISSUED:
48 49
18 MAY 2000
REPLACEMENT GANG-BAR/LOCKING ARM INSTALLATION
Find No. Description

1 PNV06-3-12 bracket assembly
2 AN3-7A bolt
3 AN960PD-10 washer
4 MS21042-3 nut
5 PNV03-3-15 fitting (REF)
6 NAS517-4-6 screw, (2 ea.) (REF)
7 AN960PD416 washer, (2 ea.) (REF)
8 MS21042-4 nut, (2 ea.) (REF)
9 DELETED
10 PNV03-7-3 locating guide (to be discarded after installation)
11 PNV03-7-5 U-Channel (Gang bar)
12 AN960PD-10 washer, (14 ea.)
13 AN3-13 bolt, (7 ea.)
14 PNV03-3-4 bushing, (7 ea.)
15 MS24665-132 cotter pin, (7 ea.)
16 AN310-3 nut, (7 ea.)
17 PNV03-3-1 swivel arm assembly, (7 ea.)
18 PNV03-9-3 spring, (7 ea.)
19 AN3-12 bolt, (7 ea.)
20 AN960-10 washer, (14 ea.)
21 AN960-416L washer, (14 ea.)
22 AN310-3 nut, (7 ea.)
23 MS24665-132 cotter pin, (7 ea.)
24 PNV03-9-1 spring, master, (2 ea.)
25 New AN3-10A bolt, (4 ea.) (REF)
26 AN960PD-10 washer, (4 ea.) (REF)
27 MS21042-3 nut, (4 ea.) (REF)
28 AN5-13 bolt
29 AN960PD-516L washer, (2 ea.)
30 AN310-5 nut
REVISION: “C”
“B”
“G” 23
17
24
20 DECEMBER
NOVEMBER
MARCH
JULY 2005
20042003
ISSUED:
50
18 MAY 2000

31 MS24665-132 cotter pin
32 PNV06-3-11 hydraulic cylinder bracket (REF.)
33 PNV06-1-13 fitting , (2 ea.) (REF)
34 9557K23 (SKYDROL), 9464K23 “O” ring, (2 ea.) (5606 Hyd. Fluid) (REF)
35 PNV06-3-1 hydraulic cylinder
36 AN5-13 bolt
37 AN960PD-516 washer, (4 ea.)
38 AN320-5 nut
39 MS24665-132 cotter pin
40 PNV06-3-3 clevis (REF)
41 AN316-4 nut (REF)
42 AN960PD-416 Washer (4 ea.)
43 MS21042-4 Nut ( 2 ea.)
44 DELETED
45 PNV03-9-7 Tab (2 ea.)
46 AN4-13A Bolt (2 ea.)
47 DELETED
48 PNV03-3-5 bracket (REF)
49 PNV03-9-5 spring tab (REF)
50 PNV03-3-100 Template (for PNV06-3-13 Bracket)
51 DELETED
52 PNV21-0-45 Template
53 PNV03-1-25 Lock Block (2 ea.)
54 AN4-20A Bolt (4 ea.)
55 AN960PD-416 Washer (8 ea.)
56 MS21042-4 Nut (4 ea.)
58 MS20470AD5-5 rivets (20 ea.)
REVISION: “C”
“E”
“B” 17
23
29
24 AUGUST
NOVEMBER
DECEMBER
MARCH 2004
2004
2003
ISSUED:
51
18 MAY 2000
50 (FN 1)
UP
FWD
FIGURE 6
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
52
18 MAY 2000
ALIGN PRECISELY WITH

EDGE OF SKIN
2
3
4
(FN 6)
(FN 7)
(FN 8)
(FN 5)
FIGURE 6-1 UP
CYLINDER SUPPORT
BRACKET INSTALL FWD
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
53
18 MAY 2000
INTENTIONALLY LEFT BLANK
REVISION: “E”
“B” 17
30 AUGUST
NOVEMBER
DECEMBER
2004
2003
ISSUED:
54
18 MAY 2000
REVISION: “C”
“E”
“B” 17
24 AUGUST
NOVEMBER
MARCH 2004
2004
2003
ISSUED:
55
18 MAY 2000
REVISION: “C”
“E”
“B” 17
24 AUGUST
NOVEMBER
MARCH 2004
2004
2003
ISSUED:
56
18 MAY 2000
REPLACEMENT GANG-BAR/SWIVEL ARM INSTALLATION
Fwd Edge of Torque Tube Cover Channel (REF)

MS20470AD5 Rivets FIGURE 6-6
(3 pl. each) (REF) TYPE I & TYPE II DOORS ONLY
Torque Tube Cover Channel (REF)

51 FIGURE 6-7
TYPE I & TYPE II DOORS ONLY
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
57
18 MAY 2000
23
(FN 11) 22
2X 12
21 2X
13 20 2X
14 19
16
(FN 48)
18
15
17
UP
BEFORE
AFTER
FIGURE 6-8 FWD

LOCKING ARM DETAIL
7 PL. TYP.
(FN 18)
REVISION: “C”
“E”
“B” 17
24 AUGUST
NOVEMBER
MARCH 2004
2004
2003
ISSUED:
58
18 MAY 2000
REVISION: “C”
“E”
“B” 17
24 AUGUST
NOVEMBER
MARCH 2004
2004
2003
ISSUED:
58 59
18 MAY 2000
45 42 43 44 46
UP
FWD
(FN 49) 24
Latch No. 3 & 5
(REF) FIGURE 6-10
TENSION SPRING INSTALLATION AT
LATCH 3 AND LATCH 5
REVISION: “C”
“E”
“B” 17
23
24 AUGUST
NOVEMBER
DECEMBER
MARCH 2004
2004
2003
ISSUED:
60
18 MAY 2000
REPLACEMENT
REPLACEMENT
GANG-BAR/LOCKING
U-BAR/LOCKING ARM
ARMINSTALLATION
INSTALLATION
DETAIL 1 DETAIL 2
DETAIL 1
Gang Bar AFT End (REF)
54
FWD
53 55 2X
56
DETAIL 2
Gang Bar FWD End (REF)
FIGURE 6-11
REVISION: “C”
“B”
“D” 23
17
13
24 DECEMBER
NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
61
18 MAY 2000
33 34
35
FIGURE 6-12
UN-LOCKING HYDRAULIC
CYLINDER
(FN 40) (FN 41) 28
6X 36 NOTE: FIGURE IS PICTURE USED AS
FIND NUMBER IDENTIFICATION 29
37 REFERENCE ONLY. ACTUAL
COMPONENTS MAY APPEAR 30
38
DIFFERENT.
39 31
(FN 59)
(FN 52)
FIGURE 6-13
FIGURE 6-13
REVISION: “C”
“B”
“F” 13
17
23
24 JANUARY
NOVEMBER
DECEMBER
MARCH 2004
2005
2003
ISSUED:
61 62
18 MAY 2000
ACTUATOR BLOCK/MICRO-SWITCH INSTALLATION
9.3.5 New Actuator Block and Micro-switch Installation.

NOTE: Alternate position for switch assembly template is between latch positions #5 and #6.
(1) Place switch assembly installation template (FN 17) between torque tube cover channels between
latch positions #3 and #4 (fwd and aft edges must be precisely vertical). {Location Ref Fig. 6-
14} and drill from four holes in template through lower inner door skin with #10 bit. Drill one
hole and install 3/16” cleco before drilling second hole. Install 3/16” cleco in second hole before
drilling third and fourth holes. With 3/16” clecos in all four holes, drill the #40 pilot holes (8 pl)
and #10 fastener holes (4 pl.).
(2) Discard template and install anchor nuts (FN 15) 4 pl. Use rivets (FN 16).
NOTE: Wiring must be installed to switch assembly {Ref. Chapter 8}.
(3) Install switch assembly (FN 1) with screws (FN 9) and washers (FN 10) 4 pl. {Ref Fig. 6-16}
CAUTION: GANG BAR MUST BE SECURED IN THE LOCKED POSITION BEFORE PROCEEDING.
(4) With gang bar in locked position, install drill templet (FN 18) on upper two screws (FN 9) and
#40 drill from template to mark gang bar, 2 places (1/16” deep MAX). {Ref Fig. 6-15}
CAUTION: DO NOT DRILL THROUGH GANG BAR IN STEPS (4) OR (5). 1/16” AND
1/8” DEEP AS INDICATED
(5) 1/4” drill through #40 holes in drill template (FN 18) into gang bar, 2 places (1/8” deep MAX).
(Ref. Fig. 6-15)
(6) Clamp actuator (FN 11) in place centered over the two 1/4” drill marks in gang bar and 1/4” drill
from actuator through gang bar.
(7) Install actuator (FN 11) using bolts (FN 12), washers (FN 13) and nuts (FN 14). {Ref Fig. 6-16}
NOTE: Test by engaging all pins to the locked position. Now the switch should be fully engaged by ap-
proximately 1/4 inch over travel. {Ref Fig. 6-16} (Overtravel is the distance from switch contact
to the end of travel)
REVISION: “C”
“B”
“F” 13
17
24 JANUARY
NOVEMBER
MARCH 2004
2005
2003
ISSUED:
63
18 MAY 2000
ACTUATOR BLOCK INSTALLATION
1 PNV07-3-101 Switch Installation Assembly

(with PNV07-3-1 switch, 2 ea.)
2 ILB
3 PNV07-3-1 Switch (REF) (S15)
MS24694-8R18 Screw (3 pl), AN960PD-08L Washer (3 pl) (REF)
MS21042-08 Nut (3 pl) (REF)
4 PNV07-3-1 Switch (REF) (S2A)
MS21042-08 Nut (3 pl) (REF)
5 MS3470W8-33S Connector w/ sockets (REF)
MS3476W8-33P Connector w/ pins (REF)
MS35206-215 Screw (4 pl), AN960PD-04L Washer (4 pl) (REF)
PNV07-9-213 Nut Plate (REF)
6 MS3470W8-33SW Connector w/ sockets (REF)
MS3476W8-33PW Connector w/ pins (REF)
PNV07-9-213 Nut Plate (REF)
7 ILB
8 MS25281-R5 (REF)
AN525-8R8 Screw, AN960PD-8L Washer (REF)
MS21042-08 Nut (REF)
9 AN525-10R10 Screw (4 ea)
10 AN960PD-10 Washer (4 ea)
11 PNV03-1-27 Actuator
12 AN4-20A Bolt (2 ea)
13 AN960PD-416 Washer (2 ea)
14 MS21042-4 Nut (2 ea)
15 MS21059-L3 Anchor Nut (4 ea)
16 CCR264SS3-4 Rivet (8 ea)
17 PNV21-0-39 Switch Assembly Installation Template
18 PNV21-0-51 Drill Template
REVISION: “C”
“E”
“B” 17
23
29
24 AUGUST
NOVEMBER
DECEMBER
MARCH 2004
2004
2003
ISSUED:
64
18 MAY 2000
FIGURE 6-14
TEMPLATE LAYOUT
REVISION: “C”
“B”
“F” 13
17
24 JANUARY
NOVEMBER
MARCH 2004
2005
2003
ISSUED:
65
18 MAY 2000
Top two screws in

Switch Assembly
(FN 1)
(FN 18) Gang Bar (REF)
Switch Assembly
(FN 1)
FIGURE 6-15
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
65 66
18 MAY 2000
ACTUATOR BLOCK AND MICRO-SWITCH INSTALLATION
12
11 9 15
13
14 10 16
FWD UP
LATCH #6 (FN 3) (FN 5) 1 (FN 6) (FN 4)
(FN 8)
LATCH #5
FIGURE 6-16
LIMIT SWITCH INSTALLATION
(Looking outboard)
REVISION: “C”
“B”
“D” 17
13
24 NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
67
18 MAY 2000
REVISION: “C”
“B”
“D” 23
17
13
24 DECEMBER
NOVEMBER
MAY
MARCH
2004
20042003
ISSUED:
68
18 MAY 2000
CHAPTER 3
VENT DOOR INSTALLATION

PREPARATION AND
AIRCRAFT MODIFICATIONS
REVISION: “D”
17 MAY
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
69
18 MAY 2000
1) Remove all insulation covering window or window plug.

2) Remove 10 fastening clips securing window plug.
3) Remove window.
4) Save fastening clips and rubber seal for re-use.
5) Clean area of debris thoroughly before installing new NASI vent
UP
door. (Chapter 4)
LOOKING FWD
OUTBOARD
CARGO DOOR
FIGURE 7
REMOVE WINDOW PLUG MODEL 100
AT AREA SHOWN
CARGO DOOR
FIGURE 7a
REMOVE WINDOW PLUG MODEL 200
AT AREA SHOWN
REVISION: “D”
17 MAY
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
69 70
18 MAY 2000
Remove existing rivets,

two in each attachment
clip.
Remove existing
attachment clips.
(May be anchor
nuts instead of
clips)
Fig. 7-2
REVISION: “D”
17 MAY
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
71
18 MAY 2000
CHAPTER 4
VENT DOOR INSTALLATION
REVISION: “D”
17 MAY
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
72
18 MAY 2000
9.3.6 VENT DOOR ASSEMBLY INSTALLATION
Install vent door assembly as follows: {Fig. 8}
(1) Align pilot holes in angles (FN 2) and (FN 3) with rivet holes (from attachment clip removal
Ref Fig. 7-2) and install rivets (FN 4) (4 pl).
(2) Hold angles (FN 2) and (FN 3) to maintain alignment of angle inner flange and window frame
web inner edge, clamp in place {Ref Fig. 8-1} and drill (#40) from rivet holes in window
frame web through angles (FN 2) and (FN 3).
(3) Install angles (FN 2) and (FN 3) with rivets (FN 4) (16 pl) {Ref Fig. 8-2}.
(4) Install vent door assembly (FN 1) in window frame with existing or new seal installed. Use
clips (FN 13), screws (FN 14) and washers (FN 15).
(5) Install the cable assembly (FN 5) into the Aft side bracket. See Fig. 8-4 for cable installation
reference.
(6) Install the two springs (FN 6) in top two brackets (FN 18) and (FN 19) .
(7) Thread rod end (FN 16) onto cable assembly (FN 5) with a minimum of 10 threads into the
cable stud.
(8) Stretch the Aft side spring and install to lower bracket (FN 20) with eye bolt (FN 8).
(9) Stretch the forward side spring and install to lower bracket (FN 20) with eye bolt (FN 8).
(10) Coil the control cable and set aside away from the door. The following steps will install the
vent door’s actuating handle. The cable’s free end will be installed in §9.3.11.
(11) Remove MS21042-08 nut with AN960PD-8 washer from aft position on vent door hinge, and
install existing grounding strap using MS21042-08 nut with AN960PD-8 washer as removed
{Ref Fig 8-3 & 8-4}.
NOTE: Step (12) may not apply as interior varies.
(12) Trace cut-out from template (FN 17) on support strap, 1/4” drill at forward and aft inside
corners of cut-out and cut 2” x 15” piece from support strap as illustrated. {Ref Fig. 8-1}
(13) Paint exterior of vent door assembly to match exterior of aircraft.
REVISION: “D”
REVISION: “C”
“B” 13
17
23
24 MAY
NOVEMBER
DECEMBER
MARCH 20042003
2004
ISSUED:
73
18 MAY 2000
VENT DOOR ASSEMBLY INSTALLATION

PARTS LIST

1 PNV01-1-1 vent door assembly
2 PNV13-1-91 Angle-Frame, 2 ea.
3 PNV13-1-93 Angle-Frame, 2 ea.
4 CCR264SS3-6 Rivet, 20 ea.
5 PNV11-3-5 control cable assembly
6 PNV11-3-7 spring, 2 ea.
7 INTENTIONALLY BLANK
8 AN43B11 eye bolt, 2 ea.
9 AN960-PD416 washer, 4 ea.
10 AN310-4 nut, 2 ea.
11 MS24665-132 cotter pin, 2 ea.
12 DELETED
13 PNV01-1-27 Clip, 10 ea.
14 AN525-8R6 Screw, 10 ea.
15 AN960PD-08 Washer, 10 ea.
16 PNV11-1-15 Rod End
20 PNV01-3-11 bracket (2 ea.) (REF)
REVISION: “D”
REVISION: “C”
“B” 24
17 MARCH
23
29
13 NOVEMBER
DECEMBER
MAY 20042003
2004
ISSUED:
73 74
18 MAY 2000
17
Angle inner flange
Window frame web

inner edge
Fig. 8-1
FS 440 FS 420 (model –100 REF)

FS 460 FS 440 (model –200 REF)
Fig. 8-2
REVISION: “D”
REVISION: “C”
“B” 13
17
24 MAY
NOVEMBER
MARCH 20042003
2004
ISSUED:
74 75
18 MAY 2000

Aft fastener on vent door (lower hinge
half), attach existing grounding strap
{REF}
13
14
15
(FN 1)
Existing window
plug grounding
strap {REF}
(FN 20) FIG. 8-3
5 (FN 18) (FN 19)
6
FEMALE
ROD END 16
1
2X 6
UP
(FN 6)
(FN 20) FIG. 8-4 FWD

VENT DOOR
8 9 10 11 GENERAL ARRANGEMENT
LOOKING OUTBOARD
2X
REVISION: “D”
17 MAY
23
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
76
18 MAY 2000
CHAPTER 5
VENT DOOR EXTERNAL ACTUATING

HANDLE ASSEMBLY INSTALLATION
REVISION: “D”
17 MAY
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
76 77
18 MAY 2000
9.3.7 VENT DOOR EXTERNAL ACTUATING HANDLE ASSEMBLY INSTALLATION
Install vent door external actuating handle assembly as follows:
(1) Mark one single dark pencil line parallel with and up 10.00 (+.50/-.00) inches from top of inner
skin joggle {Ref Fig. 9}.
(2) As shown in Figure 9-1, position the drill guide (FN 1) so it hits against the forward edge of the
door. Center the 3/8 diameter hole to be in-line with the pencil line (10.00 (+.50/-.00) inches
up from top of inner skin joggle) and “C” clamp to sandwich the door securing the drill guide
in place.
(3) Using a 3/8 diameter drill bit, drill thru the drill guide’s 3/8 diameter hole thru the aircraft inner
skin only.
(4) Using a 3/8 diameter drill bit, go outside of the aircraft and drill thru the outer skin using the
drill guide. (FN 1) {Fig. 9-1}
(5) Remove the drill guide and using a step-drill (Unibit), enlarge the inner and outer holes to 3/4”
diameter. {Fig. 9-2, outer hole}
CAUTION: PLACING THE BEARING HORIZONTALLY IS VITAL.

INTERNAL PARTS MUST CORRECTLY ALIGN WHEN ASSEMBLED.
(6) Place bearing (FN 2) thru outer and inner skin 3/4 diameter hole (do not force, slip-fit required).
Align the slot parallel to the aircraft’s horizontal center line. Assure that the two steps on the
bearing channel area are facing aft. {Fig. 9-3}
Transfer the hole pattern in the bearing flange thru the aircraft outer skin using a #30 drill bit.
After drilling all 20 holes, remove the bearing from the door.
(7) Apply pressure sealant PR1422 B1/2 or CS3204 B1/2 to flange of bearing (FN 2) and install
with rivets (FN 3) and (FN 4) wet.
(8) Position the housing (FN 5) on the bearing (FN 2) protrusion and pivot the housing (FN 5)
until it is perfectly parallel to the forward edge of the cargo door {Fig. 9-4}. Mark outline of
housing (FN 5) on cargo door inner skin and set housing (FN 5) aside.
(9) Remove MS20470AD6 rivets as required within the housing outline marked on the cargo door
inner skin. (Ref. Fig. 9)
(10) Countersink and install (FN 24) or (FN 25) rivets (as required) as removed in step (9). (Ref.
Fig. 9)
(11) Reposition housing (FN 5) per step (8) #10 drill the twelve holes from the housing through the
cargo door inner skin {Fig. 9-4}.
REVISION: “E”
REVISION: “C”
“B” 17
17
23
24 AUGUST
NOVEMBER
DECEMBER
MARCH 20042003
2004
ISSUED:
77 78
18 MAY 2000
9.3.7 VENT DOOR EXTERNAL ACTUATING HANDLE ASSEMBLY INSTALLATION
(12) Remove the housing (FN 5) and by using the twelve #10 holes, place an anchor nut drilling jig with a .344 hole
spacing to locate the rivet hole pattern for the twelve anchor nuts (FN 6) that will be installed in step (13).
(13) Install twelve anchor nuts (FN 6) using rivets (FN 7).
(14) Install housing (FN 5) with bolts (FN 16) and washers (FN 17) 12 pl.
(15) Install “O” ring (FN 9) into the groove of handle assembly shaft (FN 8) {Ref Fig. 9-7} and apply silicone dry
lubricant to “O” ring and bearing (FN 2) bore.
(16) Install handle assembly (FN 8) into bearing (FN 2) with spring (FN 15) and actuator (FN 14) in housing as
illustrated {Fig. 9-6}.
(17) With handle assembly (FN 8) and actuator (FN 14) in locked position {Ref Fig. 9-10} install primary shear pin
(FN 10) and secondary shear pin (FN 13) with washers (FN 11) and cotter pins (FN 12) as illustrated in Fig. 9-6.
CAUTION: DO NOT HAMMER SHEAR PINS IN ACTUATOR HANDLE ASSEMBLY
NOTE: THE RED AND GREEN SHEAR PINS ARE COLORED FOR INSTALLATION LOCATION.
(18) Install roll pin (FN 22) in handle assembly {Fig. 9-6}
(19) Test assembly operation integrity by assuring that while the handle is in the locked position, the “GREEN” flag
{Fig. 9-10} will be visible as looking from the cargo compartment access door in the 9G barrier. Handle should
slide easy into the bearing slot and securely remain in that position. Pull handle out of the slot and rotate CCW to
the stop in the bearing.
Now the “RED” flag should be the one visible from the cargo compartment access door. {Fig. 9-9} Repeat this
process several times until there is assurance that the operation of the handle is satisfactory.
(20) Install placard (FN 20) as illustrated in Fig. 9-8.
(21) a) On an aircraft with a 9G bulkhead, install placard (FN 21) on forward side of 9G bulkhead 54 inches up from
floor along edge of cargo compartment access door .
b) Aircraft with 9G Net, install placard (FN 21).
9.3.8 INSTALL STOP (FN18) as follows:
(1) Position stop (FN18) as illustrated in Fig. 9-6, push outboard against inner skin and forward against forward door
frame and remove fasteners in frame located beneath stop (FN18). From resultant fastener holes, back drill all
holes resulting in 1½ diameter minimum edge distance thru stop (FN18), and install rivets (FN 23) or screws in
remaining fastener holes, which will not be used for rivets through stop (FN 18).
(2) Install stop (FN18), use fasteners (FN 19).
(3) Cut cargo liner vertical support strap (Location FS 480) along horizontal support straps. Cut location indicated by
flag 1 . {Ref Fig. 9-6}.
NOTE: NO CARGO LINER OR CARGO LINER TAPE MAY BE INSTALLED OVER THE STOP (FN 18).
REVISION: “G”
REVISION: “C”
“B” 20
17
29
24 JUL
NOVEMBER
DECEMBER
MARCH
200520042003
ISSUED:
79
18 MAY 2000
VENT DOOR EXTERNAL ACTUATING HANDLE ASSEMBLY INSTALLATION

PARTS LIST
1 PNV13-3-65 drill guide (Fixture)
2 PNV13-3-63 bearing
3 MS20426AD4-6 rivet, 16 ea.
4 MS20426AD4-10 rivet, 4 ea.
5 PNV13-3-51 guard assembly (housing)
6 MS21059-L3 anchor nut, 12 ea.
7 CCR264SS3-4 rivet, 24 ea.
8 PNV05-3-51 handle assembly
9 AS3582-014 “O” ring
10 PNV05-5-1 primary shear pin (green)
11 AN960PD10L washer, 2 ea.
13 PNV05-5-3 secondary shear pin (red)
14 PNV05-1-51 actuator
15 PNV05-3-57 spring
16 AN3-6A bolt, 12 ea.
17 AN960-PD10 washer, 12 ea.
18 PNV05-1-61 stop
19 MS20470AD6-10 rivet or MS20470AD6-12 rivet, AR
(ALT: AN3-( ) with MS21042-3 nut or equivalent bolt and nut)
20 PNV10-1-5 placard
22 92373A369 roll pin
23 MS20426AD6-12 rivet, AR (alt: NAS517-3-( ) screw)
24 MS20426AD6-5 rivet, AR
25 MS20426AD6-6 rivet, AR
REVISION: “G”
17 JULY
23
30 NOVEMBER
DECEMBER
2005 2003
ISSUED:
79 80
18 MAY 2000
Hole to be drilled Mark a centerline

from drill guide parallel to longerons
Remove rivets within outline. Countersink and install

MS20426AD rivets.
FIGURE 9
10.00
inch Reference
Joggle: “Small offset along edge of sheet or strip to

Joggle allow it to overlap adjacent compo-
nents” — Jane’s Aerospace Dictionary
REFERENCE AID
TO INSTALLER
Ref. For Fig. 9

Marking Location
REVISION: “E”
REVISION: “C”
“B” 17
17
23
24 AUGUST
NOVEMBER
DECEMBER
MARCH 20042003
2004
ISSUED:
80 81
18 MAY 2000
Marked
Centerline
UP
FWD
Cargo Door
Inner Skin 1
Cargo Door
Outer Skin
“C” Clamp
3/8 DIA DRILL

UP
FIGURE 9-1 AFT

DOOR DRILLING OPERATION
REVISION: “D”
REVISION: “C”
“B” 13
17
24 MAY
NOVEMBER
MARCH 20042003
2004
ISSUED:
82
18 MAY 2000
STEP-DRILL TO 3/4 DIA.

OUTSIDE
UP
FIGURE 9-2 AFT

STEP-DRILL TO SIZE
LOOKING INBOARD
17 DECEMBER
NOVEMBER 2003
ISSUED:
83
18 MAY 2000
STOP FACING UPWARDS

BEARING (FN 2) SLOT MUST
BE PARALLEL TO AIRCRAFT
CENTERLINE 3 16 X
1
ALL
AROUND
4X 4 UP
AFT
FIGURE 9-3
RIVETING OPERATION
HANDLE BEARING
LOOKING INBOARD
NOTE: THE VENT DOOR AND WARNING SYSTEM CANNOT BE PROPERLY RIGGED IF THE HANDLE
DOES NOT LOCK-IN HORIZONTALLY AND PARALLEL TO THE AIRCRAFT CENTER LINE
BEARING MUST BE INSTALLED AS SHOW.
REVISION: “D”
17 MAY
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
84
18 MAY 2000
KEEP PARALLEL
FIG 9-5
Bearing (FN 2)
Protrusion
#10 Transfer
Drill thru Inner
Skin (11 pl)
16
17
12X
6
Joggle
8
FIG 9-4 9
REVISION: “D”
17 MAY
30 NOVEMBER
DECEMBER
2004 2003
ISSUED:
85
18 MAY 2000

Horizontal Support Strap
22 (Cargo Liner) RED
13 GREEN
PIN 10 11 12
PIN
1
11
(FN 15)
23 12
(FN 8)
18
19 AR 14
No cargo liner or cargo

3.00 inches +.50 liner tape may be installed
-.00 over Stop (FN 18).
Horizontal Support Strap

(Cargo Liner)
Vertical Support Strap

(Cargo Liner)
FIGURE 9-6 (FN 9) (FN 8)

Actuator Stop Installation FS 480
15
FIGURE 9-7
Handle Assembly
REVISION: “E”
REVISION: “C”
“B” 24
17 MARCH
17 NOVEMBER
AUGUST2004
20042003
ISSUED:
85 86
18 MAY 2000
LOOKING
OUTBOARD
21
FIGURE 9-7
DOOR OPERATION PLACARD
(Typ. Installation with 9G Bulkhead Net)
BEARING
STOP
LOOKING
INBOARD
(FN 2)
(FN 8)
20
UP
FIGURE 9-8 AFT

DOOR OPERATION PLACARDS
REVISION: “G”
REVISION: “C”
“B” 20
17
29
24 JULY
NOVEMBER
DECEMBER
MARCH 20042003
2005
ISSUED:
87
18 MAY 2000
LOOKING 27
OUTBOARD
26
3.50
FIGURE 9-8A
DOOR OPERATION PLACARDS
FIGURE 9-8B FIGURE 9-8C

PNV10-1-11 PLACARD PNV10-1-13 PLACARD
REVISION: “G”
REVISION: “C”
“B” 20
17
29
24 JUL
NOVEMBER
DECEMBER
MARCH
200520042003
ISSUED:
87 88
18 MAY 2000
“RED FLAG
“DOOR OPEN”
FWD
EXTERNAL
UP
FIGURE 9-9
VENT DOOR OPEN FLAG
LOOKING AFT FROM AFT
CARGO ACCESS DOOR
REVISION: “D”
“G” 17 MAY
30
20 NOVEMBER
DECEMBER
JUL 2004 2003
2005
ISSUED:
89
18 MAY 2000
“GREEN FLAG
“DOOR CLOSED”
EXTERNAL
FWD
UP
FIGURE 9-10
VENT DOOR CLOSED FLAG
AFT
LOOKING AFT FROM
CARGO ACCESS DOOR
REVISION: “D”
“G” 17 MAY
30
20 NOVEMBER
DECEMBER
JUL 2004 2003
2005
ISSUED:
90
18 MAY 2000
CHAPTER 6
CARGO DOOR GANG BAR

BLOCKERS/CONTROL CABLE
ASSEMBLY INSTALLATION
NOTE: FIGURES 10-2, 10-5 & 10-7 ARE SKIPPED

AND DO NOT EXIST.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED:
90 91
18 MAY 2000
GANG BAR BLOCKER/CONTROL CABLE ASSEMBLY INSTALLATION
9.3.9 GANG-BAR BLOCKERS ASSEMBLY INSTALLATION (FIG. 10 & 10-1):
CAUTION: AN960-616 WASHERS MUST BE INSTALLED BETWEEN LATCH ASSEMBLY AND BLOCKER (FN 1).
(1) Place upper torque tube cover channel cut-out template (FN 99) on channel, positioned between latches #1 & #2 and push
against cargo door inner skin and fwd against aft edge of doubler as illustrated in Fig. 10-3 (see Fig 10-3 for cut-out
reference). Be sure template is against doublers and against inner skin, and trace cut-out with marker. Repeat procedure for
channel cut out on aft side of Latch #6.
(2) Drill 1/4 inch hole through channel at corners of cut-out, and cut out as marked from channel with a die grinder.
CAUTION: DO NOT CUT INTO OR NICK INNER SKIN OF CARGO DOOR WITH GRINDER
(3) Cut outboard flange of channel with die grinder. Do not cut through filler between channel and cargo door inner skin.
(4) Drill out three MS20426AD6 rivets (remove fasteners) in newly cut section of section of channel flange and remove flange
from channel.
a) Cut and remove portions of upper channel for cable passage (5 pl.). Do NOT cut through outboard flange. Fig 10-6 &
Fig 11.
(5) Countersink filler at resultant holes and install MS20426AD6-5 (3 pl). (filler to cargo door inner skin)
(6) Repeat steps (1) through (5) between latches #6 & #7
NOTE: Have electrician run wire for switches S1 and S2 before installing blockers.
NOTE: AN960-616 washer must be installed between Blocker Assembly (FN 1) and Latch Assembly. See insert Fig. 10 & 10-1.
(7) Install forward blocker assembly (FN 1) with blocker (FN 5) between latch assembly #1 & #2 and install bolts and washers
(FN 2) through Blocker Assembly (FN 1) and latch base. (See insert Fig. 10)
(8) Install aft Blocker Assembly (FN 1) with Blocker (FN 5) between latch assembly #6 & #7 and install bolts and washers (FN
2) through blocker assembly (FN 1) and latch base. (See insert Fig. 10-1)
9.3.10 DELETED
REVISION: “E”
REVISION: “C”
“B” 17
“G” 17
23
24 AUGUST
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
91 92
18 MAY 2000
9.3.11 CONTROL CABLE INSTALLATION (FIG. 10-6):

(1) Place anchor nut templates (FN 70 - FN 80, FN 82-85 & FN 100) on cargo door inner skin per Fig. 10-5 and drill indi-
cated holes from template through cargo door inner skin.
(2) Install MS21059-L3 anchor nuts as indicated (Ref 1 ) on cargo door inner skin (per anchor nut templates) using
CCR264SS3-4 rivets (AR). (Includes anchor nuts for electric conduit Ref Fig. 12-4)
(3) Hold the upper cargo door sill template (FN 69) in place against the forward cargo door lift cylinder aft fitting and drill
the indicated holes for anchor nuts (3 pl). Also drill indicated pilot holes for R5-NAS-113 and R5-NAS-115 connectors
while template (FN 69) is still in place. Enlarge center hole in R5-NAS-113 and R5-NAS-115 to Ø 0.63 and the screw
holes for each connector to 7/64 (4 pl. ea.)
(4) Install MS21059-L3 anchor nuts (3 pl) on upper cargo door sill per template (FN 69) using CCR264SS3-4 rivets (6 pl).
(5) Install bracket (FN 6) with spring (FN 101) 2 pl. using bolts (FN 9) and washers (FN 10), 8 pl each. {Ref. Fig 10-3}.
(6) Attach control cable (FN 7) through lower outboard hole in guard assembly (FN 64) using washers (FN 67) and nuts (FN
68) secure with 0.025” diameter safety wire. {Ref Fig. 10-4}
(7) Attach control cable (FN 8) through lower inboard hole in guard assembly (FN 64) using washers (FN 67) and nuts (FN
68). Secure with 0.025” diameter safety wire. {Ref Fig. 10-4}
(8) Attach control cable (FN 27) through upper outboard hole in guard assembly (FN 64) using washers (FN 67) and nuts
(FN 68) secure with 0.025” diameter safety wire. {Ref Fig. 10-4}
(9) Lift blockers (FN 5) as far up as possible and with a 1/4” drill bit or centerpunch piloted through rod end connecting hole
in top end of blocker (FN 5), mark and drill through cargo door inner skin. Lower blockers and enlarge hole to 1/2”.
This will allow the fastener (FN 50) to be installed, attaching rod end (FN 17) to blocker (FN 5). {Ref. Fig 10-3}
(10) Attach control cables (FN 7 & FN 8) through brackets (FN 6) using washers (FN 65) and nuts (FN 66) with 0.025”
safety wire at forward and aft blocker assemblies. {Ref Fig. 10-3}
(11) Screw rod ends (FN 17) on control cables (FN 7 & FN 8) fourteen full turns and secure with jam nut (FN 16).
(12) Attach control cables (FN 7 & FN 8) and rod ends (FN 17) to forward and aft blockers (FN 5) using screw (FN 50),
washer (FN 51) and nut (FN 52) 2 pl ea. Screw is installed in blocker (FN 5) through hole drilled in step (9) {Ref Fig.
10-3}.
(13) Thread control cable (FN 27) behind cargo liner brackets from just above cargo door to vent door, and insert end of con-
trol cable into the control cable bracket on the vent door assembly. {Ref Fig. 10-6}
NOTE: NOTCH GILL LINER SUPPORT (FLANGES ONLY) AS REQUIRED FOR CONTROL CABLE.
(14) Control cable (FN 27) passes behind the horizontal cargo door liner mounting brackets and is secured with P-clips (FN
61) and attaching hardware. {Ref Fig. 10-9}
REVISION: “E”
REVISION: “C”
“B” 17
“G” 17
29
24 AUGUST
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
92 93
18 MAY 2000
NOTE: Measure 32.00 ± 0.25 inches along control cable (FN 27) from top of bracket (FN 43) and mark control cable. Align
mark on control cable (FN 27) with aft edge of bracket (FN 88) secured to upper door sill. Ref flag note 1 , Fig.
10-6.
(15) Install brackets (FN 43 & FN 88) using screws (FN 89) and washers (FN 90) 6 pl. per Fig. 10-6.
(16) Secure control cable (FN 27) to bracket (FN 43 & FN 88) using clamps (FN 45) and attaching hardware 6 pl per Fig 10-
6.
(17) Secure control cable (FN 8) to cargo door inner skin with P-clips (FN 44) and attaching hardware (3 pl.) and P-Clips (FN
94) with attaching hardware. Secure control cable (FN 7) with P-Clips (FN 44) and attaching hardware (7 pl.). {Ref Fig.
10-6}
(18) Secure control cables (FN 27) to cargo door inner skin with P-clips (FN 63) and attaching hardware 5 pl ea. per Fig 10-6.
(19) Secure control cable (FN 27) to inbd fuselage structure using clamps (FN 93) and attaching hardware 3 pl and (FN 61) (4
pl.). {Ref Fig. 10-9}
(20) At the ends of cable assemblies (FN 7 & 8) assure that a drilled nut (NAS509-4) is threaded at the end of each assembly.
Thread a rod (FN 29) on each cable end with a minimum of ten full threads, do not tighten. (Only these two cables get a
rod (FN 29)). {Ref Fig. 10-4}
(21) Install a rod end (FN 24) at the end of the (FN27) vent door actuating cable. (Fig. 10-4) Assure that the rod end has a
check nut (AN316-4) threaded in it.
NOTE: Bolt (FN 31) must be installed with head outboard for clearance.
(22) With the actuator (FN 28) up to the “Green” closed position, attach the rod end (FN 24) into the actuator outboard upper
hole using a bolt (FN 31), two washers (FN 32), a nut (FN 33) and a cotter pin. (FN 34) External handle is at the closed
position. {Ref Fig. 10-4}
NOTE: For steps (23)(a) thru (e), Fig. 8-4 in Chapter 4.
(23) To adjust the vent door actuating cable (FN 5):
a) Place external handle in the locked position.
b) Remove the aft eye bolt (FN 8) to disconnect vent door cable from vent door.
c) Hold vent door fully closed.
d) Adjust the cable (FN 5) length to align hole in rod end (FN 16) with hole in bracket (FN 20), allowing the eye bolt to
be installed with the vent door fully closed.
e) Once this adjustment is achieved, lengthen the cable by one full 360-degree turn of the rod end (FN 16).
Reinstall all hardware as it is shown in Fig. 8-4 in Chapter 4.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
93 94
18 MAY 2000

(24) Verify both ends of the vent door control cable have proper engagement of threads in rod ends (inspect
witness holes in rod ends)
(25) Next step requires that the vent door is in the “Open” position. Rotate the external actuating handle to the
fully open position. (The vent door will open)
(26) The following steps will adjust the length of the two blocker actuating cable assemblies. It is required that the two
blockers (FN 5) be manually lifted, held all the way up with the cargo door gang-bar (FN 4) in the “open” unlocked
position. (All pins out) (Ref. Fig. 10)
CAUTION: Bolts (FN 31) must be installed with head outboard for clearance. (Fig 10-4)
(27) With the external handle still in the “open” position, install the forward cable assembly (FN 7) to the green side
of the actuator (FN28) outboard hole using a bolt (FN 31), two washers (FN 32), a nut (FN 33) and a cotter pin
(FN 34). Install the AFT actuating cable assembly (FN 8) to the green side of the actuator (FN28) inboard hole
using a bolt (FN 31), two washers (FN 32), a nut (FN 102) and a cotter pin (FN 34). {Fig. 10-4}
(28) Rotate vent door handle (FN 8) to the closed position. Do not push handle into the slot in bearing (FN 2) at this
time. {Ref Fig. 9-8}
(29) Adjust control cables (FN 7 & 8) to lower blockers (FN 5) until they make contact with stop (switch housing (FN 13))
{Ref Fig. 10-1 for component location—not illustrated with blocker down in locked position}
(30) With vent door closed, push vent door handle (FN 8) into bearing slot (FN 2) (Ref. Fig. 9-8). Rig blockers as follows:
a) Adjust control cables (FN 7 & 8) until both blockers (FN 5) clear stops (switch housing (FN 13)) with .003 clearance.
(Ref. Fig. 10)
b) With the vent door handle, open and close the vent door and recheck the .003 clearance between the blockers (FN 5)
and the switch housing stop (FN 13) (Ref. Fig. 10).
(31) Rotate vent door handle open and closed. When the vent door handle is fully rotated closed to the stop on bearing
(FN 2). When released, the handle should remain against the stop. Perform §(30) again if the handle springs back from
the locked position. (Ref. Fig. 9-8)
(32) Once all the cables are installed and properly adjusted, check all witness holes for proper thread engagement and tighten
all fasteners and safety wire the two rods (FN 29) with .020 stainless safety wire.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
94 95
18 MAY 2000
GANG-BAR BLOCKER/CONTROL CABLE ASSEMBLY INSTALLATION
9.3.12 VENT DOOR GUARD AND DRAIN INSTALLATION

(1) Test the system for operational compliance several times to assure that everything is working smoothly and to
satisfaction. Any doubts should justify re-testing and re-adjusting if necessary. Once the installation is
satisfactory, then install the vent door guard assembly (FN 39) as follows:
a) Place guard assembly (FN 39) over vent door. Assure that drain assembly (FN 36) and draining nipple face
downwards, and install using screws (FN 40) and washers (FN 41), 14 pl. each. {Fig. 10-7}
(2) Attach drain line tube (FN 38) to the guard assembly (FN 39) on the bottom drain nipple. Use worm gear hose
clamp (FN 37).
(3) Route drain line (FN 38) underneath the floor along fuselage skin.
(4) Route the drain line forward 80 inches attaching the drain line to the flanges of the frame stations using
MS25281-R7 P clips, AN525-10R9 screws, AN960-PD10L washers and MS21042-3 nuts. To best judgment
locations.
(5) Route the drain line (FN 38) down under the floor to existing drain vent. Attach approximately every 20
inches using P-Clips (FN 98) with attaching hardware.
(6) Attach the vent door drain line (FN 38) to existing drain fitting using worm gear clamp (FN 96). If existing
drain fitting connections are not available, then remove one of the drain elbows and replace elbow with a tee
fitting (FN 97).
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
96
18 MAY 2000

1 PNV03-1-1 blocker assembly, 2 ea.
2 NAS1306-18 bolt, 4 ea.
AN960-616 washer, 8 ea.
3 DELETED
4 PNV03-7-5 U-Channel (Gang bar) (REF)
5 PNV03-1-7 blocker, 2 ea.
6 PNV03-1-5 cable bracket, 2 ea.
7 PNV11-3-3 control cable, AFT location
8 PNV11-3-1 control cable, Forward location
9 AN3-6A bolt, 8 ea.
10 AN960PD-10 washer, 8 ea.
11 MS21059-L3 anchor nut, 8 ea.
12 DELETED
13 PNV07-3-15 Switch (REF)
14 DELETED
15 DELETED
16 AN316-4 nut, 2 ea. (REF)
17 PNV11-1-15 rod end 2 ea.
18 PNV03-1-25 lock block, 2 ea. (REF)
19 AN4-20A bolt, 4 ea. (REF)
20 AN960PD-416 washer, 8 ea. (REF)
21 MS21042-4 nut, 4 ea. (REF)
22 DELETED
23 DELETED
24 PNV11-1-15 rod end, 1 ea.
25 DELETED
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
97
18 MAY 2000

26 DELETED
27 PNV11-3-5 control cable assy. (REF)
28 PNV05-1-51 actuator (REF)
29 PNV11-1-9 Rod Assy 2 ea., (PNV11-1-17 Rod & PNV11-1-11 Rod End, 2 ea.)
30 PNV11-1-11 Rod End, 2 ea. (REF)
31 AN4-10 bolt, 3 ea.
32 AN960PD-416L washer 6 ea.
33 AN310 - 4 nut, 3 ea.
35 DELETED
36 PNV13-3-71 Drain Assembly (REF)
37 13014 Worm Gear Clamp
38 PNV13-1-85 drain line
39 PNV13-1-73 guard assy.
40 AN525-8R8 screw, 14 ea.
41 AN960PD-08 washer, 14 ea.
42 DELETED
43 PNV11-3-21 Bracket
44 MS25281-R6 P-Clip, NAS1096-3-10 screw,
AN960-PD10 washer, 11 ea.
45 MS21919DG6 clamp, NAS1096-3-10 screw,
AN960-PD10 washer, 6 ea.
46 DELTED
47 DELETED
48 DELETED
49 DELETED
50 NAS517-4-9 screw, 2 ea.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
98
18 MAY 2000

51 AN960PD-416 Washer, 2 ea.
52 MS21042-4 Nut, 2 ea.
53 DELETED
54 DELETED
55 DELETED
56 DELETED
57 DELETED
58 DELETED
59 MS21061-L3 Anchor Nuts (AR)
60 CCR264SS3-4 Rivets (AR)
61 MS25281-R6 P-Clip, AN960PD-10 Washer
NAS1096-3-10 Screw, MS21042-3 Nut, 3 pl.
62 MS25281-R3 P-Clip (REF), 2 pl.
63 MS25281-R6 P-Clip, AN3-12A Bolt,
94369A146 Spacer, AN960P10-10 Washer, 5 pl.
64 PNV13-3-51 Guard Assembly (REF)
65 AN960-1016 Washer, 4 ea. (REF)
66 PNV11-3-23 Drilled Nut, 4 ea. (REF)
67 MS20002-10 Washer, 4 ea. (REF)
68 PNV11-3-23 Drilled Nut, 4 ea. (REF)
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
99
18 MAY 2000

81 DELETED
86 MS21059-L3 Anchor Nuts (53 pl)
87 CCR264SS3-4 Rivets (106 pl)
88 PNV11-3-16 Bracket
89 NAS1096-3-10 Screw, 6 ea.
90 AN960PD-10L Washer, 6 ea.
91 PNV21-0-39 Template (REF)
92 INTENTIONALLY BLANK
93 MS25281-R6 P-Clip, NAS623-3-9 Screw,
AN960PD-10 Washer, MS21042-3 Nut, 3 ea.
94 PNV11-3-11 Spacer, MS25281-R6 P-Clip
AN3-10A Bolt, AN960PD-10 Washer
95 DELETED
96 13014 Worm Gear Clamp, 2 ea.
97 PNV13-1-87 Tee Fitting
98 MS25281-R7 P-Clip, NAS1096-3-10 Screws
AN960PD-10 Washers, MS21042-3 Nuts, 15 ea.
101 PNV03-1-33 Spring
102 AN320-4 Nut
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED:
100
18 MAY 2000
(FN 19)
(FN 20) (FN 4)
(FN 21) 18 5
FIGURE 10
GANG BAR BLOCKER
FORWARD INSTALLATION
(FN 13)
1 (FN 62) 2
LATCH
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
Tecumseh, MI 49286 NASI CHAPTER 6 100 101
ISSUED: 18 MAY 2000
(FN 13)
(FN 5) (FN 5)
FIGURE 10-1
1 2 LATCH #6
INSERT
FIGURE 10-1
GANG BAR BLOCKER
AFT INSTALLATION
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
23
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
FIGURE 10-2
9 7
10 8
11
65
6 66
DOUBLER
{Ref §9.3.9(1)}
101
16 AFT EDGE OF
DOUBLER
17
FWD EDGE OF
Channel outboard flange TEMPLATE ALIGNED
cut and remove rivets. AGAINST AFT EDGE
{Ref §9.3.9(3) & (4)} OF DOUBLER
50
99
51
52 CUT OUT (REF)
FIGURE 10-3
GANG BAR BLOCKERS INSTALLATION, 2 PL. TYPICAL
REVISION: “G”
REVISION: “C”
“B” 13
“D” 17
29
24 MAY
03
20 NOVEMBER
DECEMBER
MARCH
APRIL
JUL 200520042003
2004
2005
ISSUED: 18 MAY 2000

34
31
102
27
24
28
30 2X 34
33
2X
32 2X
31
29 2X
FN 64
67
68
FN 8
UP
FN 7
FWD OUTBOARD
FIGURE 10-4
INSTALLING CONTROL CABLES AT
BLOCKER/DOOR HOUSING FWD LOCATION,
LOCKED POSITION LOOKING OUTBOARD
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
FIGURE 10-5
TEMPLATE LAYOUT
REVISION: “F”
REVISION: “C”
“B” 13
“G” 17
24 JANUARY
20 NOVEMBER
MARCH
JUL 200520042003
2005
ISSUED: 18 MAY 2000
(FN 63)
REF Fig. 10-9

DETAIL 5
(FN 61)
(FN 27)
DETAIL 6
(FN 93)
REF Fig. 10-8

DETAIL 4
(FN 8)
(FN 44)
DETAIL 2
(FN 7)
(FN 94)
(FN 7)
(FN 8)
DETAIL 1
FIGURE 10-6
CONTROL CABLES SCHEMATIC
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
(FN 27) USE EXISTING TYPE

FASTENER
(FN 88)
45
DETAIL 7
(FN 43)
DETAIL 3
UP
45 89
FWD
90
DETAILS 3 &7
FIGURE 10-6
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
29
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
41
40
36 39
37
UP
38
FWD
FIGURE 10-7
INSTALLING CONTROL CABLES AT
BLOCKER/DOOR HOUSING FWD
LOCATION, LOCKED POSITION
LOOKING OUTBOARD
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
(FN 93)
FIGURE 10-8
(FN 93)
(FN 61)
FIGURE 10-9
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
29
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
CHAPTER 7
HYDRAULIC SYSTEM INSTALLATION
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
HYDRAULIC SYSTEM INSTALLATION

9.4.1 MODIFY CARGO DOOR HYDRAULIC SYSTEM AS FOLLOWS:
NOTE: (1) The new hydraulic lock cylinder FXV06-3-1 was installed in Chapter 2, (Ref. Fig. 6-11)
(2) Install hydraulic line (FN 1) installed on the forward fitting on lock cylinder and forward existing bulkhead fitting.
(3) Install the second hydraulic line (FN 2) on the aft fitting of the lock cylinder and aft existing bulkhead fitting.
* (4) Remove pressure relief valve PRI and adjust for 2800 PSI +/- 75 PSI and reinstall valve. Ref. Appendix G, Note 1
* (Ref. PNV-727-MM, Fig 528, 52-30-00, page 526)
(FN 3) (FN 1)
(FN 2)
FIGURE 11
HYDRAULIC CYLINDER

1 FXV06-1-19 Hydraulic Line
2 FXV06-1-17 Hydraulic Line
3 MS25281-R6 P-Clip, 8 ea.

NSA1096-3-10 Screw, AN960PD-10 Washer, MS21042-3 Nut
REVISION: “F”
REVISION: “C”
“B” 13
“G” 17
24 JANUARY
20 NOVEMBER
MARCH
JUL 200520042003
2005
ISSUED: 18 MAY 2000
9.4.2 REPLACE LATCH SEQUENCE SWITCH ACTUATOR BRACKETS

NOTE: BOTH S1 and S3 sequence switches are reused and must be undamaged.
1) Remove #10 fasteners securing latch sequence switch brackets (FN 1) to cargo door and remove
latched sequence switch (FN 2) and unlatched sequence switch (FN 4) with actuators and
brackets. Ref. Fig. 11-2 and 11-2.
2) Remove latched sequence switch (FN 2) and unlatched sequence switch (FN 4) from existing
switch actuators illustrated in Fig. 11-3.
3) Install new latched and unlatched sequence switch mount brackets (FN 7 and 8) with new bolts
(FN 9), washers (FN 10) and nuts (FN 11).
CAUTION: DO NOT INSTALL S1 latched sequence switch (FN 2) or S3 unlatched sequence

switch (FN 4) at this time. Severe damage to switches may occur.
4) Assemble latched sequence switch (FN 2) and unlatched sequence switch (FN 4) in new switch
actuators (FN 5 and 6). Ref. Fig. 11-4
NOTE: Reference Appendix E, PEMCO AEROPLEX, INC. Maintenance Manual “Rigging Main
Cargo Door”. Adjust latches open sequence switch and adjust latches closed sequence switch.
5) With cargo door fully unlatched, install S3 unlatched sequence switch (FN 4) in bracket (FN 8)
with .040±.005 inches of overtravel. See Appendix E, page 2.
6) With cargo door fully latched, install S1 latched sequence switch (FN 2) in bracket (FN 7)
with .028±.005 inches of overtravel. See Appendix E, page 2.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
LATCH SEQUENCE SWITCH ACTUATOR BRACKETS PARTS LIST
1 Latched sequence switch bracket Existing
2 S1 latched sequence switch Existing
3 Unlatched sequence switch bracket Existing
4 S3 unlatched sequence bracket Existing
5 PNV11-3-25 switch actuator New
6 PNV11-3-25 switch actuator New
7 PNV11-3-23 switch bracket New
8 PNV11-3-23 switch bracket New
9 AN3-5A bolt (4 ea.) New
10 AN960PD-10 washer (8 ea.) New
11 MS21042-3 nut (4 ea.) New
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
LATCH SEQUENCE SWITCH ACTUATOR BRACKETS REPLACEMENT
EXISTING SWITCH
1 MOUNT BRACKET
2 S1 LATCHED
SEQUENCE SWITCH
FIGURE 11-1
EXISTING SWITCH
3
MOUNT BRACKET
S3 UNLATCHED
SEQUENCE SWITCH 4
FIGURE 11-2
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
LATCH SEQUENCE SWITCH ACTUATOR BRACKETS REPLACEMENT
EXISTING SWITCH ACTUATOR
S1 OR S3
FIGURE 11-3
EXISTING S1 OR S3 SEQUENCE
SWITCH ASSEMBLED WITH
EXISTING SWITCH ACTUATOR
(FN 5) OR (FN 6)
NEW SWITCH S1 OR S3
ACTUATOR LATCH
SEQUENCE
SWITCH
FIGURE 11-4
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
CHAPTER 8
CARGO DOOR
ELECTRIC SYSTEM INSTALLATION
REVISION: “D”
“G” 17 MAY
30
20 NOVEMBER
DECEMBER
JUL 2004 2003
2005
ISSUED: 18 MAY 2000
9.5.1 CARGO DOOR ELECTRIC SYSTEM REWORK

Rework existing electric wiring per drawings PNV-24-1703, PNV-24-1575, PNV-24-2085 and PNV-
ER-0-8 as follows:
(1) Rewire switch S2A per drawing PNV-24-1703. Ref: Appendix A.
(2) Rework remaining wiring per drawing PNV-24-1703. Ref: Appendix A.
(3) Remove and rework wiring per drawing PNV-24-1575. Ref. Appendix B.
(4) If maintenance monitor panel installed, remove and rework wiring per drawing PNV-24-2085.
Ref. Appendix D.
(5) Rework cargo door wiring per diagram PNV-ER-0-8. Ref: Appendix C.
NOTE: REMOVE ALL WIRE ASSOCIATED WITH REMOVED AND DISCARDED

COMPONENTS.
CAUTION: ALL FREE (UNUSED) WIRE ENDS MUST BE CAPPED AND STOWED IN
ACCORDANCE WITH AC 43.13-1B, CHAPTER 11, SECTION 8.
9.5.2 CARGO DOOR ELECTRIC SYSTEM INSTALLATION

NOTE: Figure 12 shows the location of panels in the cockpit.
NOTE: All wiring and electric components installations to be done using NASI drawings numbers
PNV-ER-0-8, PNV-24-1575 and PNV-24-1703. These drawings are included in this
PNV-727-12 document’s end as “Appendix “A, B, C”.
NOTE: Unless otherwise stated, protect and clamp wire bundles in accordance with AC43.13-1B,
chapter 11.
(1) Pin relay connectors per PNV-ER-0-8 and install relay bracket (FN 1) using screws (FN 4),
washers (FN 5) and nuts (FN 18) 2 pl. ea. {Fig 12-5}
(2) Install relay (FN 2) and (FN 3). {Fig 12-5}
(3) Install circuit breakers (FN 7, 9 & 11) and placards (FN 6, 8 & 10) at circuit breaker locations
per Fig 12-1 & PNV-ER-0-8.
(4) Install bracket (FN 28) {Fig 12-4, Detail G}
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000

(5) Install connectors (FN 29, 30, 31 & 32) per Fig 12-4 Detail G, use nut plate (FN 33) all four places.
Ref Fig 10-5 template layout template (FN 69 & 70) for connector and connector bracket locations.
(6) Install cable assemblies (FN 12 & 13) {Fig 12-4, Detail G}
(7) Wire routing per Figure 12-4
Install all electrical hardware as follows:
(8) Remove the existing cargo warning light located in the right flight engineers panel below the smoke
detector panel and plug resulting holes.
(9) Install warning lights (FN 14) and (FN 15) as follows: {Fig. 12-2}
(a) Locate position for warning lights on fwd instrument panel. Ref. Fig 12-2
(b) Make two square cut outs with dimensions of .695 inch horizontal and .695 inch vertical as it is
shown on Figure 12-2. If that is not possible, make cut outs in available location in pilot center
panel.
NOTE: If required, fabricate new panel.
(c) Deburr cut-outs thoroughly at inner and outer surfaces of panel.
(d) Remove lens assemblies from warning lights (FN 14) and (FN 15).
(e) Loosen mount screws until corner mounts swivel inside the housing.
(f) Insert warning light (FN 14) through the upper cut-out and (FN 15) thru the lower cut-out.
(g) Tighten mount screws until warning lights are firmly mounted in the instrument panel.
(h) Install the lens assemblies.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
15
23
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
(10) Install vent door warning light (FN 17) and in transit light (FN 16) as follows:
{Fig. 12-3}
(a) Locate an area on the cargo door control panel where the new cargo door warning lights can
be positioned. Figure 12-3 show possible location.
(b) Remove existing cargo door warning lights from control panel.
(c) Using the existing hole for the “Warning” lights as a location, enlarge to a .755 inch
horizontal by .755 inch vertical rectangular hole.
(d) Make a second .755 inch horizontal by .755 inch vertical rectangular cut-out on the same
vertical center line either above or bellow the first cut-out.
(e) Deburr both cut-outs thoroughly on the inside and outside surfaces.
(f) Remove lens assembly from warning lights (FN 16) and (FN 17).
(g) Loosen mount screws until corner mounts swivel inside the housing.
(h) Insert warning light (FN 17) through the upper cutout and (FN 16) through the lower cut-
out.
(11) Remove any debris , metal shavings and leftover wire from all panels areas and aircraft.
(12) Replace all panels using the existing fasteners.
(13) Wire cargo door area per drawing PNV-ER-0-8.
(14) After the installation of all items in this installation manual, an operational check must be
performed and is specified in the next chapter (9).
REVISION: “E”
REVISION: “C”
“B” 17
“G” 17
23
24 AUGUST
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
CARGO DOOR ELECTRIC SYSTEM INSTALLATION PARTS LIST

1 PNV07-5-25 Relay Mount Bracket
2 PNV07-5-3 relay
3 PNV07-5-1 relay
4 NAS1096-2-6 Screws, 2 pl.
5 AN960PD-08 Washers, 2 pl.
6 PNV10-1-3 “CARGO DOOR “B” WARNING” placard
7 PNV07-7-1 “CARGO DOOR “B” WARNING” circuit breaker (C2)
8 PNV10-1-1 “CARGO DOOR “A” WARNING” placard
9 PNV07-7-1 “CARGO DOOR “A” WARNING” circuit breaker (C1)
10 PNV10-1-2 “CARGO DOOR IN-TRANSIT” placard
11 PNV07-7-1 “VENT AND CARGO DOOR IND” circuit breaker (C3)
12 PNV07-9-201 Cable Assembly
13 PNV07-9-203 Cable Assembly
14 PNV07-1-1, “A” warning light
15 PNV07-1-2, “B” warning light
16 PNV07-1-4 “In-transit” indicator light
17 PNV07-1-3 “Vent Door” warning light
18 MS21042-08 Nuts, 2 pl.
19 MS25281-R3 or –R4 P-Clip, NAS1096-3-10 Screws, AN960PD-10 Washers, MS21042-3 nuts, 5 pl.
20 MS25281-R5 P-Clip, NAS1096-3-10 Screws, AN960PD-10 Washers, MS21042-3 nuts, 16 pl.
21 534017 flexible sleeve, AR
22 MS35489-11 Grommet, 3 pl.
23 MS35489-6 Grommet, 7 pl.
24 NAS1033A3 Nut Plate (or equivalent), 7 pl.
25 DELETED
26 MS25281-R3 Clamp, NAS1096-3-10 Screw, AN960PD-10 Washer, MS21042-3 nut 3 pl. ea.
27 MS25281-R2 Clamp
28 PNV11-3-19 Bracket 1 ea., AN525-10R7 Screw, AN960PD-10 Washer, MS21059-L3 Anchor Nut, 3 pl. ea.
29 MS3470W10-6P Connector
30 MS3470W10-6S Connector
31 MS3470W10-6PW Connector
32 MS3470W10-6SW Connector
33 PNV07-9-215 Nut Plate 4 ea., MS35206-4R6 Screw, AN960PD-04L Washer, 16 pl. ea.
34 PNV07-1-27 Control Panel Plate
35 PNV07-1-29 Control Panel Plate
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
15
23
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
CARGO DOOR ELECTRIC SYSTEM INSTALLATION
STEP 3 1) Remove Aft equipment panel cover.

2) Remove Aft Upper equipment panel cover.
ELECTRICAL ACCESS 3) Remove Circuit Breaker access panel.
PANELS REMOVAL 4) Remove Access panel to flight engineers panel.
CAUTION! LIVE VOLTAGE

INJURY OR DEATH TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT CAN OCCUR!
RETAIN ALL HARDWARE FOR RE-INSTALLATION
P6
P11
P4
J3
FIGURE 12
LOOKING AFT
CONTROL CABIN
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
C2
C1
C3
4) All wire routed in flexible sleeve to original indicated

bus on vent door wiring diagram PNV-ER-0-8.
3) C3 - second row up, fourth position from inbd
1) C1 - lower row, fourth position from inbd
2) C2 - lower row, third position from inbd
NOTES:
FIGURE 12-1a
CIRCUIT BREAKERS PLACARDS
FLIGHT ENGINEER STATION AT
CIRCUIT BREAKERS PANEL
REVISION: “G”
17 JUL
NOVEMBER
2005 2003
ISSUED: 18 MAY 2000
10 11
8 9
6 7
FIGURE 12-1b
P6-2 PANEL ALTERNATE LOCATION
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
15
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
14 15
FIGURE 12-2
P2-3 FWD CONTROL PANEL
REVISION: “F”
REVISION: “C”
“B” 13
“G” 17
15
24 JANUARY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2005
ISSUED: 18 MAY 2000
16
17
FIGURE 12-3A
MAIN CARGO DOOR
(P-13) CONTROL PANEL
FIGURE 12-3B
MAIN CARGO DOOR
(P-32) CONTROL PANEL 16
17
34
35
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
15
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
Grommet
(FN 22)
(FN 27)
DETAIL E
(FN 19)
DETAIL F
(FN 20)
DETAIL D
(Next Page)
DETAIL G
(FN 21)
7/16”
7/16”
7/16”
5/8”
ELECTRIC CONDUIT SCHEMATIC

(FN 20)
(FN 21)
(FN 24)
3 pl
FIGURE 12-4
DETAIL C
CENTERLINE
Drill 5/8 Hole, Install
Grommet (FN 23)
(FN 19)
DETAIL F
DETAIL B
(FN 26)
DETAIL A
(FN 21)
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
15
29
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
12 29 32 28
13
31
30 33
FIGURE 12-4, DETAIL G

ELECTRICAL
CONNECTORS
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
1 2 3
0.25
6.50
18
P6-4 PANEL
FIGURE 12-5
RELAY INSTALLATION
P6-4 PANEL
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
MS35489-11
Grommet (REF)
(Put service loop W638-9156-20
in wire bundle for W638-9157-20
switch assembly) ( in flexible sleeve)
(REF)
(S15 REF) FS 550.00

(S2A REF)
Alternate Location:
FS 590.00
FIGURE 12-5, DETAIL A
REVISION: “F”
REVISION: “C”
“B” 13
“G” 17
30
24 JANUARY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2005
ISSUED: 18 MAY 2000
W638-9149-20 W638-9151-20
W638-9147-20 W638-9150-20
(Both in flexible (Both in flexible
sleeve) REF sleeve) REF
SERVICE
LOOP (REF)
W638-9149-20 MS35489-11
W638-9147-20 Grommet
FS 620 (Both in flexible FS 600.00
sleeve) REF
PASSING THRU GROMMET:
W638-9156-20, W638-9158-20 (in flexible sleeve)
REF
FIGURE 12-5, DETAIL B
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
W638-9147-20
W638-9149-20
(both in flexible
sleeve) REF
W638-9150-20
W638-9151-20
(both in flexible
sleeve) REF
W638-9144-20 SERVICE
W638-9146-20 LOOP (REF)
(both in flexible
sleeve) REF FS 520.00 FS 500
FIGURE 12-5, DETAIL C
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
FS 590.00 FS 580.00 FS 570.00
FIGURE 12-5, DETAIL D
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
CHAPTER 9
VENT DOOR SYSTEM
OPERATIONAL TEST PROCEDURE
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
9.6 VENT DOOR SYSTEM OPERATIONAL TEST

NOTE: FOR TROUBLESHOOTING REFER TO CHARTS IN THE NASI VENT DOOR MAINTENANCE
MANUAL NASI-PNV-MM, PARAGRAPHS 52-30-80 AND 52-70-80.
9.6.1 VENT DOOR MECHANICAL OPERATIONS CHECK

(1) Ensure cargo door is completely closed, latched and locked.
(2) Close vent door as follows:
I) Rotate the handle 100 degrees clockwise. Ensure handle locks in slot.
II) Inspect the vent door assembly PNV01-0-1 to ensure the vent door is fully closed against the
seal.
NOTE: IF THE VENT DOOR FAILS TO CLOSE FULLY AGAINST THE SEAL, THE VENT DOOR
GUARD ASSEMBLY WOULD HAVE TO BE REMOVED AND READJUST, Control Cable Assy.
REF §9.3.11(23).
(3) Inspect the FORWARD blocker PNV03-1-7 for 1.50 inches of travel or greater. (From fully up to
fully down.)
NOTE: IF THE FWD BLOCKER’S IS OUTSIDE THIS RANGE, RE-ADJUST THE CABLE LENGTH AS
EXPLAINED IN §9.3.11, Control Cable Assy. Instl. STEPS (29) and (30).
(4) Inspect the aft blocker PNV03-1-7 for 1.50 inches of travel or greater. (From fully up to
fully down)
NOTE: IF THE AFT BLOCKER’S IS OUTSIDE THIS RANGE, READJUST THE CABLE LENGTH AS
EXPLAINED ON §9.3.11, Control Cable Assy. Instl. STEPS (29) and (30).
(5) Open vent door as follows:
I) Pull out on handle and rotate the handle 100 degrees counterclockwise to the handle stop.
II) Inspect the vent door assembly PNV01-0-1 to ensure it has opened.
NOTE: INSURE THAT THE HANDLE REMAINS IN THE FULL OPEN POSITION FOR THE
FOLLOWING STEPS (6) AND (7).
(6) Inspect the FORWARD blocker PNV03-1-7. The blocker should be pulled up.
a) Ensure there is clearance between the blocker and the lock block (PNV03-1-25).
b) Ensure there is clearance between the blocker and the torque tube.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
VENT DOOR SYSTEM OPERATIONAL TEST
(7) Inspect the AFT blocker PNV03-1-7. The blocker should be pulled up as far as possible.
a) Ensure that there is clearance between the blocker and the lock block.
b) Ensure that there is clearance between the blocker and the torque tube.
9.6.2 CARGO DOOR OPERATIONAL CHECK

NOTE: During test monitor cargo door A & B warning lights on pilot instrument panel.
(1) Open Cargo Door as follows:
I) Place ARM/DISARM switch to the ARM position.

Position door control switch (at cargo door control panel). Hold in this position until the
cargo door is completely open.
II) Inspect to ensure the Cargo Door unlocks completely.
NOTE: IF THE CARGO DOOR FAILS TO UNLOCK, INSPECT THE HYDRAULIC SYSTEM FOR
FAULTY VALVES, PUMPS, AND RELAYS. THEN RE-CHECK.
(2) Close Cargo Door as follows:
I) Position door control switch close. Hold in this position until the cargo door is
completely closed, latched and locked.
II) Inspect to ensure the Cargo Door closes against the door jamb.
NOTE: IF THE CARGO DOOR FAILS TO CLOSE, INSPECT THE HYDRAULIC SYSTEM FOR FAULTY
VALVES, PUMPS AND RELAYS.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
(3) Inspect to ensure the Cargo Door latches completely.

NOTE: IF THE CARGO DOOR FAILS TO LATCH, INSPECT THE HYDRAULIC SYSTEM FOR
FAULTY VALVES, PUMPS, AND RELAYS.
(4) Inspect to ensure the Cargo Door locks completely.
NOTE: IF THE CARGO DOOR FAILS TO LOCK, OTHERWISE INSPECT THE HYDRAULIC
SYSTEM FOR FAULTY VALVES, PUMPS AND RELAYS.
9.6.3 WARNING SYSTEM OPERATIONAL CHECK

Begin this check with the vent and cargo door open.
(1) Inspect cargo door A warning light PNV07-1-1 to ensure it is illuminated.
NOTE: IF CARGO DOOR A WARNING LIGHT PNV07-1-1 FAILS TO ILLUMINATE, CHECK
THE CIRCUIT AND ENSURE THAT SWITCH S1 IS DISENGAGED AND RELAY ASSY
PNV07-5-1 IS DE-ENERGIZED.
(2) Inspect cargo door B warning light PNV07-1-2 to ensure it is illuminated.
NOTE: IF CARGO DOOR B WARNING LIGHT PNV07-1-2 FAILS TO ILLUMINATE, CHECK
THE CIRCUIT AND ENSURE THAT SWITCH S2 IS DISENGAGED AND RELAY ASSY
PNV07-5-3 IS DE-ENERGIZED.
(3) Inspect vent door warning light PNV07-1-3 to ensure it is illuminated.
NOTE: IF VENT DOOR WARNING LIGHT PNV07-1-3 FAILS TO ILLUMINATE, CHECK THE
CIRCUITRY FOR OPENS OR SHORTS.
(4) Inspect the cargo door in–transit light PNV07-1-4 to ensure it is illuminated.
(5) Position door control switch in the cargo door closed position. Hold in this position until the
cargo door is completely closed, latched and locked.
(6) Inspect the cargo door in–transit light PNV07-1-4 to ensure it has extinguished.
NOTE: IF CARGO DOOR IN-TRANSIT LIGHT PNV07-1-4 IS ILLUMINATED, CHECK THE
CIRCUITRY FOR SHORTS AND ENSURE THAT SWITCH S25 IS ENGAGED.
(7) Close the vent door as follows:
I) Rotate the vent door handle PNV05-3-51 assembly 100 degrees counter clockwise.
II) Inspect the Vent Door to ensure it has closed.
III) Inspect the Fwd and Aft Blockers PNV03-1-7 to ensure they travel 1.50 or greater.
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
(8) Inspect cargo door A warning light PNV07-1-1 to ensure it has extinguished.
NOTE: IF CARGO DOOR A WARNING LIGHT PNV07-1-1 REMAINS ILLUMINATED, CHECK

THE CIRCUITRY FOR AN OPEN OR SHORT. INSPECT SWITCH S1 TO ENSURE IT IS
ENGAGED.
(9) Inspect cargo door B warning light PNV07-1-2 to ensure it has extinguished.
NOTE: IF CARGO DOOR B WARNING LIGHT PNV07-1-2 REMAINS ILLUMINATED, CHECK

THE CIRCUITRY FOR AN OPEN OR SHORT. INSPECT SWITCH S2 TO ENSURE IT IS
ENGAGED.
(10) Inspect vent door warning light PNV07-1-3 to ensure it has extinguished.
NOTE: IF VENT DOOR WARNING LIGHT PNV07-1-3 REMAINS ILLUMINATED, CHECK

THE CIRCUIT FOR AN OPEN OR SHORT
9.6.4 CHECK THE “PRESS TO TEST” FUNCTIONS OF THE WARNING LIGHTS
(1) Press to test cargo door A warning light PNV07-1-1 to ensure it illuminates.
NOTE: IF CARGO DOOR A WARNING LIGHT PNV07-1-1 FAILS TO ILLUMINATE, CHECK

THE CIRCUIT AND ENSURE RELAY ASSEMBLY PNV07-5-1 IS ENERGIZED.
(2) Press to test cargo Door B warning light PNV07-1-2 to ensure it illuminates.
NOTE: IF CARGO DOOR B WARNING LIGHT PNV07-1-2 FAILS TO ILLUMINATE, CHECK

THE CIRCUIT AND ENSURE RELAY ASSY PNV07-5-3 IS ENERGIZED.
(3) Press to test vent door warning light PNV07-1-3 to ensure it illuminates.
NOTE: IF VENT DOOR WARNING LIGHT PNV07-1-3 FAILS TO ILLUMINATE, CHECK THE
CIRCUIT FOR CONTINUITY.
(4) Press to test cargo door in-transit light PNV07-1-4 to ensure it illuminates.
NOTE: IF CARGO DOOR IN-TRANSIT LIGHT PNV07-1-4 FAILS TO ILLUMINATE, CHECK

THE CIRCUIT FOR CONTINUITY.
END OF OPERATIONAL CHECK
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000

THE “A” AND “B” LIGHTS ON CAPT’S PANEL WILL ILLUMINATE WHEN
VENT DOOR IS UNSAFE (NOT FULLY CLOSED WITH HANDLE)
FIGURE 12-6
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
24 MAY
20 NOVEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
CHAPTER 10
INSTALLATION SIGN-OFF LIST
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
INSTALLATION SIGN OFF LIST

Ref Part Number Part Name Paragraph Fig. Find No Mech. Insp.
No.
1. PNV13-5-1 PLATE 9.3.1 (3) 3-4 1 ______ ______
2 PNV13-5-3 PLUG 9.3.1 (4) 3-4 2 ______ ______
3 PNV17-1-1 LEVER 9.3.2 (1) 4 1 ______ ______
4 PNV18-1-1 BOLT 9.3.2 (2) 4 3 ______ ______
5 (Z-52-3004) CAM (REF) 9.3.2 (3) 4 9
6 PNV03-3-5 BRACKET 9.3.2 (4) 4 10 ______ ______
7 AD03-9-5 SPRING TAB 9.3.2(4) 4-3 26 ______ ______
8 NAS464P8-64 BOLT 9.3.2(4) 4-3 27 ______ ______
9 NAS464P8-59 BOLT 9.3.2(5) 4-3 13 ______ ______
10 NASI .9338 GAUGE BAR 9.3.3(1) 5-1 24 N/A N/A

(INSPECTION TOOL)
11 NAS517-4-5 SCREW 9.3.2(9) 4-4 29 ______ ______
12 PNV21-0-47 TEMPLATE 9.3.2(10) 4-5 32 ______ ______

13 .003 IN THICK FEELER GAUGE 9.3.3.1(2) 5-8 1 N/A N/A
(INSPECTION TOOL)
14 CHECK LATCH ATTACH BOLTS 9.3.3.1(9) ______ ______
15 PNV03-3-100 TEMPLATE 9.3.4(1) 6 50 ______ ______
16 PNV06-3-13 SUPPORT BRACKET 9.3.4(2) 6-1 1 ______ ______

17 ILB
18 PNV03-7-1 DRILL GUIDE 9.3.4(3a) 6-2 9 N/A N/A
(LOCATING TOOL)
19 ILB
20 PNV03-7-5 U-CHANNEL (GANG BAR) 9.3.4(4) 6-3 11 ______ ______
21 PNV03-9-23 DRILL GUIDE 9.3.4(7) 6-4 51 ______ ______
22 PNV03-1-25 LOCK BLOCK 9.3.4(9) 6-11 53 ______ ______

23 PNV21-0-41 TEMPLATE 9.3.4(11) 6-7 57 ______ ______
24 PNV03-3-1 SWIVEL ARM ASSY 9.3.4(13) 6-8 17 ______ ______
25 PNV03-3-4 BUSHING 9.3.4(14) 6-8 14 ______ ______

26 PNV03-9-1 SPRING 9.3.4(16) 6-8 18 ______ ______
27 PNV03-9-21 DRILL GUIDE 9.3.4(17) 6-9 47 ______ ______
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000

Ref Part Number Part Name Paragraph Fig. Find Mech. Insp.
No. No.
28 PNV03-9-1 SPRING 9.3.4(17) 6-10 24 ______ ______

29 PNV03-1-29 SPACER 9.3.4 (18) 6-10 44 ______ ______
30 PNV21-0-45 TEMPLATE 9.3.4 (20) 6-13 52 ______ ______
31 PNV06-3-1 HYDRAULIC CYCLINDER 9.3.4 (21) 6-12 35 ______ ______
32 PNV21-0-55 TEMPLATE 9.3.4(25) 6-13 59 ______ ______
33 PNV21-0-39 TEMPLATE 9.3.5 (1) 6-16 17 ______ ______
34 PNV07-3-1 SWITCH ASSY 9.3.5 (3) 6-16 1 ______ ______
35 PNV21-0-51 DRILL TEMPLATE 9.3.5(5) 6-15 18 ______ ______
36 PNV03-1-27 ACTUATOR 9.3.5(6) 6-16 11 ______ ______

37 PNV13-1-91 ANGLE-FRAME 9.3.6 (1) 8-2 2 ______ ______
38 PNV13-1-93 ANGLE-FRAME 9.3.6 (1) 8-2 3 ______ ______
39 PNV01-1-1 VENT DOOR ASSY 9.3.6 (4) 8-4 1 ______ ______
40 PNV01-1-27 CLIP 9.3.6 (4) 8-3 13 ______ ______
41 PNV11-3-5 CONTROL CABLE ASSY 9.3.6 (5) 8-4 5 ______ ______
42 PNV11-3-7 SPRING 9.3.6 (6) 8-4 6 ______ ______
43 PNV11-1-15 ROD END 9.3.6(7) 8-4 16 ______ ______

44 PNV21-0-57 TEMPLATE 9.3.6 (12) 8-1 17 N/A N/A
(LOCATING TOOL)
45 PNV13-3-65 DRILL GUIDE 9.3.7 (2) 9-1 1 N/A N/A
(LOCATING TOOL)
46 PNV13-3-63 BEARING 9.3.7 (6) 9-3 2 ______ ______

47 PNV13-3-51 GUARD ASSEMBLY 9.3.7 (8) 9-4 5 ______ ______
48 PNV05-3-51 HANDLE ASSEMBLY 9.3.7 (16) 9-5 8 ______ ______
49 AS3582-014 O-RING 9.3.7 (15) 9-6 9 ______ ______

50 PNV05-1-51 ACTUATOR 9.3.7 (16) 9-6 14 ______ ______
51 PNV05-3-57 SPRING 9.3.7 (16) 9-7 15 ______ ______
52 PNV05-5-1 PRIMARY SHEAR PIN 9.3.7 (17) 9-6 10 ______ ______

53 PNV05-5-3 SECONDARY SHEAR PIN 9.3.7 (17) 9-6 13 ______ ______
54 92373A369 ROLL PIN 9.3.7 (18) 9-6 22 ______ ______

55 PNV10-1-5 PLACARD 9.3.7 (20) 9-8 20 ______ ______
56 PNV10-1-7 PLACARD 9.3.7 (21) 9-7 21 ______ ______
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000

No. No.
57 ILB
58 PNV05-1-61 STOP 9.3.8 (1) 9-6 18 ______ ______
59 PNV03-1-1 BLOCKER ASSY 9.3.9 (7) 10/11 1 ______ ______
60 PNV03-1-7 BLOCKER 9.3.9 (7) 10/11 5 ______ ______
61 ILB
62 PNV21-0-3 TEMPLATE 9.3.11 (1) 10-5 70 ______ ______
63 PNV21-0-5 TEMPLATE 9.3.11 (1) 10-5 71 ______ ______
64 PNV21-0-7 TEMPLATE 9.3.11 (1) 10-5 72 ______ ______
65 PNV21-0-9 TEMPLATE 9.3.11 (1) 10-5 73 ______ ______
66 PNV21-0-11 TEMPLATE 9.3.11 (1) 10-5 74 ______ ______

67 PNV21-0-13 TEMPLATE 9.3.11 (1) 10-5 75 ______ ______
68 PNV21-0-15 TEMPLATE 9.3.11 (1) 10-5 76 ______ ______
69 PNV21-0-17 TEMPLATE 9.3.11 (1) 10-5 77 ______ ______
70 PNV21-0-19 TEMPLATE 9.3.11 (1) 10-5 78 ______ ______

71 PNV21-0-21 TEMPLATE 9.3.11 (1) 10-5 79 ______ ______
72 PNV21-0-23 TEMPLATE 9.3.11 (1) 10-5 80 ______ ______
73 PNV21-0-27 TEMPLATE 9.3.11 (1) 10-5 82 ______ ______
74 PNV21-0-29 TEMPLATE 9.3.11 (1) 10-5 83 ______ ______
75 PNV21-0-31 TEMPLATE 9.3.11 (1) 10-5 84 ______ ______
76 PNV21-0-33 TEMPLATE 9.3.11 (1) 10-5 85 ______ ______
77 ILB
78 PNV21-0-43 TEMPLATE 9.3.9 (1) 10-3 99 ______ ______

79 PNV21-0-1 TEMPLATE 9.3.11 (3) 10-5 69 ______ ______
80 PNV03-1-33 SPRING 9.3.11 (5) 10-3 101 ______ ______
81 PNV03-1-5 CABLE BRACKET 9.3.11 (5) 10-3 6 ______ ______
82 PNV11-3-1 CONTROL CABLE 9.3.11 (6) 10-3 7 ______ ______
83 PNV11-3-3 CONTROL CABLE 9.3.11 (7) 10-3 8 ______ ______
84 PNV11-1-15 ROD END 9.3.11 (11) 10-3 17 ______ ______
85 PNV11-3-16 BRACKET 9.3.11 (15) 10-6 88 ______ ______
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
29
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
No. No.
86 PNV11-3-21 BRACKET 9.3.11 (15) 10-6 43 ______ ______
87 PNV11-3-11 SPACER 9.3.11 (17) 10-6 94 ______ ______
88 PNV11-1-9 ROD ASSY 9.3.11 (20) 10-4 29 ______ ______
89 PNV11-1-15 ROD END 9.3.11 (22) 10-4 24 ______ ______
90 PNV13-3-71 DRAIN ASSEMBLY 9.3.12 (1a) 10-7 36 ______ ______
91 PNV13-1-73 GUARD ASSEMBLY 9.3.12 (1a) 10-7 39 ______ ______
92 PNV13-1-85 DRAIN LINE 9.3.12 (2) 10-7 38 ______ ______
93 PNV13-1-87 TEE FITTING 9.3.12 (6) 1 97 ______ ______
94 PNV06-1-19 HYDRAULIC LINE 9.4.1 (2) 11 1 ______ ______
95 PNV06-1-17 HYDRAULIC LINE 9.4.1 (3) 11 2 ______ ______
96 PNV07-5-25 RELAY MOUNT BRACKET 9.5.2 (1) 12-5 1 ______ ______
97 PNV07-5-1 RELAY ASSEMBLY 9.5.2 (2) 12-5 3 ______ ______
98 PNV07-5-2 RELAY ASSEMBLY 9.5.2 (2) 12-5 2 ______ ______
99 PNV11-3-25 SWITCH ACTUATOR 9.4.2(4) 11-4 5, 6 ______ ______
100 PNV07-7-1 CIRCUIT BREAKER 9.5.2 (3) 12-1 9, 7, 11 ______ ______
101 PNV10-1-1 PLACARD 9.5.2 (3) 12-1 8 ______ ______
102 PNV10-1-2 PLACARD 9.5.2 (3) 12-1 10 ______ ______
103 PNV10-1-3 PLACARD 9.5.2 (3) 12-1 6 ______ ______
104 PNV11-3-19 BRACKET 9.5.2 (4) 12-4 28 ______ ______
105 PNV07-9-215 NUT PLATE 9.5.2 (5) 12-4 33 ______ ______
106 PNV07-9-201 CABLE ASSEMBLY 9.5.2 (6) 12-4 12 ______ ______
107 PNV07-9-203 CABLE ASSEMBLY 9.5.2 (6) 12-4 13 ______ ______
108 PNV07-1-1 “A” WARNING LIGHT 9.5.2 (8) 12-2 14 ______ ______
109 PNV07-1-2 “B” WARNING LIGHT 9.5.2 (8) 12-2 15 ______ ______
110 PNV07-1-3 VENT DOOR WARN. LT. 9.5.2 (9) 12-3 17 ______ ______
111 PNV07-1-4 IN-TRANSIT LIGHT 9.5.2 (9) 12-3 16 ______ ______
112 PNV07-1-27 CONTROL PANEL PLATE 9.5.2(9a) 12-3 34 AR
113 PNV07-1-29 CONTROL PANEL PLATE 9.5.2(9a) 12-3 35 AR
114 534017 FLEXIBLE SLEEVE 9.5.2 12-4 21 ______ ______
INSTALLATION HAS BEEN COMPLETED IN ACCORDANCE WITH THIS DOCUMENT AND
OPERATIONAL TEST PERFORMED PER §9.6
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
15
29
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
APPENDIX A
CARGO DOOR WIRING DIAGRAM

DWG. No. PNV-24-1703
Rev. F, 06 August 2004
12 SHEETS
THIS DRAWING SET APPROVED BY:
REVISION: “F”
REVISION: “C”
“B” 13
“G” 17
30
24 JANUARY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2005
ISSUED: 18 MAY 2000
APPENDIX B

Rev. B, 05 May 2000
8 SHEETS
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
APPENDIX C

DWG. No. PNV-ER-0-8
Rev. E, 25 May 2005
3 SHEETS
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
APPENDIX D

Rev. B, 25 April 2000
3 SHEETS
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
ISSUED: 18 MAY 2000
APPENDIX E
PEMCO AEROPLEX, INC.

MAINTENANCE MANUAL
“Rigging Main Cargo Door”, 52-30-00, page 509
“Main Cargo Door Electrical Switches”, 52-30-16, page 405,

Fig. 401
REVISION: “D”
REVISION: “C”
“B” 13
“G” 17
30
24 MAY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2004
147 2
ISSUED: 18 MAY 2000
REVISION: “D”
REVISION: “C”
“B” 13
17
30
24 MAY
NOVEMBER
DECEMBER
MARCH 20042003
2004
2 END
ISSUED: 18 MAY 2000
.040±.005 inches overtravel

when latches open
.028±.005 inches overtravel

when latches closed
PEMCO AEROPLEX, INC.

MAINTENANCE MANUAL
52-30-16, page 405, Fig. 401
REVISION: “D”
REVISION: “C”
“B” 13
17
30
24 MAY
NOVEMBER
DECEMBER
MARCH 20042003
2004
149 148
ISSUED: 18 MAY 2000
APPENDIX F
PACKING LIST
PNV-727-PL12
REV. G, 02 NOVEMBER 2004
REVISION: “F”
REVISION: “C”
“B” 13
“G” 17
30
24 JANUARY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2005
PAGE NO NEXT PAGE
3 4
PEMCO 727 CARGO DOOR/NASI VENT DOOR SYSTEM ISSUE: 02 NOVEMBER 2000
PACKING LIST DOCUMENT: PNV-727-PL12
ITEM PART QUANTITY PACKED

DESCRIPTION SEC./FIG. LOT/PO QTY
NO. NUMBER SHIPPED BY
1 AN820-4 CAP-FLARED Fig. 1-8 2
2 AN806-4 PLUG-FLARED Fig. 1-8 2
3 RHEEM (.5020) 9.2.4, 3-3 2
4 PNV13-5-3 PLATE 9.3.1, 3-4 1
5 PNV13-5-1 PLUG 9.3.1, 3-4 1
6 MS20426AD5-7 RIVET 9.3.1, 3-4 4
7 CS3204-B 1/2 PRESSURE SEALANT 9.3.1, 3-4
8 PNV17-1-1 LEVER SUB-ASSEMBLY 9.3.2, 4 7
9 PNV18-1-1 SPECIAL BOLT 9.3.2, 4 7
10 AN381-3-12 COTTER PIN 9.3.2, 4 7
11 PNV03-3-5 BRACKET 9.3.2, 4 7
12 NAS464P8-59 BOLT 9.3.2, 4-3 5
13 MS24665-132 COTTER PIN 9.3.2, 4-3 7
14 AN381-3-12 COTTER PIN 9.3.2, 4-3 14
15 NASI .9338 GAUGE BAR 9.3.2, 4-3 1
I 16 AN960-816L WASHER 9.3.2, 4-3 14
17 PNV03-9-5 SPRING TAB 9.3.2, 4-3 2
18 NAS464P8-61 BOLT 9.3.2, 4-3 2
I 19 AN960C-816L WASHER 9.3.2, 4-3 14
20 NAS517-4-5 SCREW 9.3.2, 4-5 14
21 AN960-416 WASHER 9.3.2, 4-5 14
22 MS21042-4 NUT 9.3.2, 4-5 14
23 PNV21-0-47 TEMPLATE 9.3.2, 4-6 1
24 PNV17-1-4 WASHER 9.3.2, 4 7
25 NAS464P4-12 BOLT 9.3.3 7
26 AN3-7A BOLT 9.3.4, 6-1 6
27 AN960PD-10 WASHER 9.3.4, 6-1 12
28 MS21042-3 NUT 9.3.4, 6-1 6
29 .003 IN FEELER GAUGE 9.3.4, 6-1 2
30 PNV06-3-12 BRACKET ASSY 9.3.4, 6-1 1
31 ILB
32 ILB
33 ILB
I 34 ILB
35 ILB
36 PNV03-7-5 U-CHANNEL 9.3.4, 6-3 1
I 37 AN960PD-10 WASHER 9.3.4, 6-8 14
38 AN3-13 BOLT 9.3.4, 6-8 7
39 PNV03-3-4 BUSHING 9.3.4, 6-8 7
40 MS24665-132 COTTER PIN 9.3.4, 6-8 7
I 41 AN310-3 NUT 9.3.4, 6-8 7
42 ILB
43 ILB
44 AN4-12A BOLT 9.3.4, 6-8 7
45 PNV03-3-1 SWIVEL ARM ASSEMBLY 9.3.4, 6-8 7
46 PNV03-9-3 SPRING 9.3.4, 6-8 7
47 AN3-12 BOLT 9.3.4, 6-8 7
I 48 AN960-10 WASHER 9.3.4, 6-8 14
REVISION: A 02 NOV 00, B 29 DEC 03, C 05 APR 04, D 17 MAY 2004, F 01 SEPT 2004
PAGE NO NEXT PAGE
4 5

49 AN960-416L WASHER 9.3.4, 6-8 14
50 AN310-3 NUT 9.3.4, 6-8 7
51 MS24665-132 COTTER PIN 9.3.4, 6-8 7
52 PNV03-9-1 SPRING, MASTER 9.3.4, 6-10 2
53 AN5-13 BOLT 9.3.4, 6-12 1
54 AN960PD-516L WASHER 9.3.4, 6-12 2
55 AN310-5 NUT 9.3.4, 6-12 1
56 MS24665-132 COTTER PIN 9.3.4, 6-12 1
57 PNV06-3-1 HYDRAULIC CYLINDER 9.3.4, 6-12 1
58 AN5-13 BOLT 9.3.4, 6-12 1
59 AN960PD-516 WASHER 9.3.4, 6-12 4
60 AN320-5 NUT 9.3.4, 6-12 1
61 MS24665-132 COTTER PIN 9.3.4, 6-12 1
I 62 AN4-13A BOLT 9.3.4, 6-10 2
I 63 ILB
64 PNV03-9-7 TAB 9.3.4, 6-10 2
65 AN960PD-416 WASHER 9.3.4, 6-10 6
66 MS21042-4 NUT 9.3.4, 6-10 4
I 67 ILB
68 PNV03-3-100 TEMPLATE 9.3.4, 6 1
I 69 ILB
70 PNV21-0-45 TEMPLATE 9.3.4, 6-13 1
71 PNV03-1-25A LOCK BLOCK 9.3.4, 6-11 2
72 AN4-20A BOLT 9.3.4, 6-11 4
73 AN960PD-416 WASHER 9.3.4, 6-11 8
74 MS21042-4 NUT 9.3.4, 6-11 4
75 PNV21-0-41 TEMPLATE 9.3.4, 6-7 1
76 MS20470AD5-5 RIVET 9.3.4, 6-7 20
77 PNV21-0-55 TEMPLATE 9.3.4, 6-13 1
78 ILB
79 PNV07-3-101 SWITCH ASSEMBLY 9.3.5, 6-16 1
80 ILB
81 ILB
82 AN525-10R10 SCREW 9.3.5, 6-16 4
83 AN960PD-10 WASHER 9.3.5, 6-16 4
84 PNV03-1-27 ACTUATOR 9.3.5, 6-16 1
85 AN4-20A BOLT 9.3.5, 6-16 2
86 AN960PD-416 WASHER 9.3.5, 6-16 2
87 MS21042-4 NUT 9.3.5, 6-16 2
88 MS21059-L3 ANCHOR NUT 9.3.5, 6-16 4
I 89 CCR264SS3-4 RIVET 9.3.5, 6-16 8
90 PNV21-0-39 TEMPLATE 9.3.5, 6-16 1
91 PNV21-0-51 DRILL TEMPLATE 9.3.5, 6-15 1
92 PNV01-1-1 VENT DOOR ASSEMBLY 9.3.6, 8-4 1
93 ILB
94 ILB
95 PNV13-1-91 ANGLE FRAME 9.3.6, 8-2 2
96 PNV13-1-93 ANGLE FRAME 9.3.6, 8-2 2
97 CCR264SS3-6 RIVET 9.3.6, 8-2 20
PAGE NO NEXT PAGE
5 6

98 PNV11-3-5 CONTROL CABLE ASSEMBLY 9.3.6, 8-4 1
99 PNV11-3-7 SPRING 9.3.6, 8-4 2
100 AN43B11 EYE BOLT 9.3.6, 8-4 2
101 AN960PD-416 WASHER 9.3.6, 8-4 4
102 AN310-4 NUT 9.3.6, 8-4 2
103 MS24665-132 COTTER PIN 9.3.6, 8-4 2
104 PNV01-1-27 CLIP 9.3.6, 8-3 10
I 105 AN525-832R6 SCREW 9.3.6, 8-3 10
106 ILB
107 AN960PD-08 WASHER 9.3.6, 8-3 10
108 PNV11-1-15 ROD END 9.3.6, 8-4 1
109 ILB
110 PNV13-3-65 DRILL GUIDE 9.3.7, 9-1 1
111 PNV13-3-63 BEARING 9.3.7, 9-3 1
112 MS20426AD4-6 RIVET 9.3.7, 9-3 16
113 MS20426AD4-10 RIVET 9.3.7, 9-3 4
114 PNV13-3-51 GUARD ASSEMBLY 9.3.7, 9-4 1
115 MS21059-L3 ANCHOR NUT 9.3.7, 9-5 12
116 CCR264SS3-4 RIVET 9.3.7, 9-5 24
117 ILB
118 PNV05-3-51 HANDLE ASSEMBLY 9.3.7, 9-5 1
119 AS3582-014 O-RING 9.3.7, 9-5 1
120 PNV05-5-1 PRIMARY SHEAR PIN 9.3.7, 9-6 1
121 AN960PD-10L WASHER 9.3.7, 9-6 2
122 MS24665-132 COTTER PIN 9.3.7, 9-6 2
123 PNV05-5-3 SECONDARY SHEAR PIN 9.3.7, 9-6 1
124 PNV05-1-51 ACTUATOR 9.3.7, 9-6 1
125 PNV05-3-57 SPRING 9.3.7, 9-7 1
126 AN3-6A BOLT 9.3.7, 9-6 12
127 AN960-PD10 WASHER 9.3.7, 9-6 12
128 ILB
129 ILB
130 PNV05-1-61 STOP 9.3.8, 9-6 1
131 MS20470AD6-10 RIVET 9.3.8, 9-6 12
132 MS20470AD6-12 RIVET 9.3.8, 9-6 12
133 PNV10-1-5 PLACARD 9.3.7, 9-8 1
134 PNV10-1-7 PLACARD 9.3.7, 9-7 1
135 92373A369 ROLL PIN 9.3.7, 9-6 1
136 MS20426AD6-12 RIVET 9.3.7, 9-6 6
137 MS20426AD6-5 RIVET 9.3.7, 9 40
138 MS20426AD6-6 RIVET 9.3.7, 9 40
139 PNV03-1-1 BLOCKER ASSEMBLY 9.3.9, 10 2
140 NAS1306-18 BOLT 9.3.9, 10 4
141 AN960-616 WASHER 9.3.9, 10 8
142 ILB
143 ILB
144 ILB
145 ILB
146 CCR264SS3-4 RIVET 9.3.9, 10 16
PAGE NO NEXT PAGE
6 7

147 PNV03-1-7 BLOCKER 9.3.9, 10 2
148 PNV03-1-5 CABLE BRACKET 9.3.11, 10-3 2
149 PNV11-3-3 CONTROL CABLE, AFT 9.3.11, 10-3 1
150 PNV11-3-1 CONTROL CABLE, FWD 9.3.11, 10-3 1
151 AN3-6A BOLT 9.3.11, 10-3 8
152 AN960PD-10 WASHER 9.3.11, 10-3 8
153 MS21059-L3 ANCHOR NUT 9.3.11, 10-3 8
I 154 NAS517-4-9 SCREW 9.3.11, 10-3 2
I 155 AN960PD-416 WASHER 9.3.11, 10-3 2
I 156 MS21042-4 NUT 9.3.11, 10-3 2
I 157 PNV11-1-15 ROD END 9.3.11, 10-3 2
158 MS21061-L3 ANCHOR NUT 9.3.11, 10-5 10
159 CCR264SS3-4 CHERRY RIVETS 9.3.11, 10-5 20
160 PNV11-1-15 ROD END 9.3.11, 10-4 1
161 PNV11-1-9 ROD ASSEMBLY 9.3.11, 10-4 2
162 ILB
163 AN4-10 BOLT 9.3.11, 10-4 3
164 AN960PD-416L WASHER 9.3.11, 10-4 6
I 165 ILB
I 166 ILB
167 AN310-4 NUT 9.3.11, 10-4 3
168 MS24665-132 COTTER PIN 9.3.11, 10-4 3
I 169 MS51521-A4 ELBOW 2
170 PNV13-3-71 DRAIN ASSEMBLY 9.3.12, 10-7 1
171 13014 WORMGEAR CLAMP 9.3.12, 10-7 2
172 PNV13-1-85 DRAIN LINE 9.3.12, 10-7 1
173 PNV13-1-73 GUARD ASSEMBLY 9.3.12, 10-7 1
174 AN525-832R8 SCREW 9.3.12, 10-7 14
175 AN960PD-08 WASHER 9.3.12, 10-7 14
176 PNV11-3-21 BRACKET 9.3.11, 10-6 1
I 177 94369A146 SPACER 9.3.11, 10-6 5
I 178 MS25281-R6 P-CLIP 9.3.11, 10-6 5
I 179 AN3-12A BOLT 9.3.11, 10-6 5
I 180 AN960PD-10 WASHER 9.3.11, 10-6 5
181 MS21919DG6 CLAMP 9.3.11, 10-6 6
182 NAS1096-3-10 SCREW 9.3.11, 10-6 6
183 AN960PD-10 WASHER 9.3.11, 10-6 6
I 184 MS25281-R6 P-CLIP 9.3.11, 10-6 11
I 185 AN960PD-10 WASHER 9.3.11, 10-6 11
I 186 NAS1096-3-10 SCREW 9.3.11, 10-6 11
187 MS25281-R6 P-CLIP 9.3.11, 10-9 3
188 AN960PD-10 WASHER 9.3.11, 10-9 3
189 NAS1096-3-10 SCREW 9.3.11, 10-9 3
190 MS21042-3 NUT 9.3.11, 10-9 3
I 191 MS21059-L3 ANCHOR NUT 9.3.11, 10-5 53
I 192 CCR264SS3-4 CHERRY RIVETS 9.3.11, 10-5 106
I 193 PNV21-0-61 TEMPLATE 9.3.11, 10-5 1
194 PNV21-0-1 TEMPLATE 9.3.11, 10-5 1
195 PNV21-0-3 TEMPLATE 9.3.11, 10-5 1
REVISION: A 02 NOV 00, B 29 DEC 03, C 05 APR 04, D 17 MAY 2004
PAGE NO NEXT PAGE
7 8

196 PNV21-0-5 TEMPLATE 9.3.11, 10-5 1
197 PNV21-0-7 TEMPLATE 9.3.11, 10-5 1
198 PNV21-0-9 TEMPLATE 9.3.11, 10-5 1
199 PNV21-0-11 TEMPLATE 9.3.11, 10-5 1
200 PNV21-0-13 TEMPLATE 9.3.11, 10-5 1
201 PNV21-0-15 TEMPLATE 9.3.11, 10-5 1
202 PNV21-0-17 TEMPLATE 9.3.11, 10-5 1
203 PNV21-0-19 TEMPLATE 9.3.11, 10-5 1
204 PNV21-0-21 TEMPLATE 9.3.11, 10-5 1
205 PNV21-0-23 TEMPLATE 9.3.11, 10-5 1
206 PNV21-0-27 TEMPLATE 9.3.11, 10-5 1
207 PNV21-0-29 TEMPLATE 9.3.11, 10-5 1
208 PNV21-0-31 TEMPLATE 9.3.11, 10-5 1
209 PNV21-0-33 TEMPLATE 9.3.11, 10-5 1
210 PNV11-3-16 BRACKET 9.3.11, 10-6 1
211 AN525-10R9 SCREW 9.3.11, 10-6 3
I 212 MS21059-L3 ANCHOR NUT 9.3.11, 10-5 53
213 AN960PD-10 WASHER 9.3.11, 10-6 3
I 214 CCR264SS3-4 RIVETS 9.3.11, 10-5 106
215 MS25281-R6 P-CLIP 9.3.11, 10-9 3
216 NAS623-3-9 SCREW 9.3.11, 10-9 3
217 AN960-PD10 WASHER 9.3.11, 10-9 3
218 MS21042-3 NUT 9.3.11, 10-9 3
219 MS25281-R6 P-CLIP 9.3.11, 10-6 2
220 AN3-10A BOLT 9.3.11, 10-6 2
221 AN960PD-10 WASHER 9.3.11, 10-6 2
222 PNV11-3-11 SPACER 9.3.11, 10-6 2
223 13014 WORM GEAR CLAMP 9.3.12 2
224 PNV13-1-87 TEE FITTING 9.3.12 1
225 MS25281-R7 P-CLIP 9.3.11 15
226 NAS1096-3-10 SCREW 9.3.11 15
227 AN960PD-10 WASHER 9.3.11 15
228 MS21042--3 NUT 9.3.11 15
229 PNV21-0-43 TEMPLATE 9.3.11, 10-3 1
230 PNV21-0-53 TEMPLATE 9.3.11, 10-5 1
231 PNV03-1-33 SPRING 9.3.11, 10-3 2
232 AN320-4 NUT 9.3.11, 10-3 2
233 PNV06-1-19 HYDRAULIC LINE 9.4.1, 11 1
234 PNV06-1-17 HYDRAULIC LINE 9.4.1, 11 1
235 MS25281-R5 P-CLIP 9.4.1, 11 8
236 NAS1096-3-10 SCREW 9.4.1, 11 8
237 AN960PD-10 WASHER 9.4.1, 11 8
238 MS21042-3 NUT 9.4.1, 11 8
239 PNV07-5-25 RELAY MOUNT BRACKET 9.5.2, 12-5 1
240 PNV07-5-3 RELAY (W/CONNECTOR & PINS) 9.5.2, 12-5 1
241 PNV07-5-1 RELAY (W/CONNECTOR & PINS) 9.5.2, 12-5 1
242 NAS1096-2-6 SCREW 9.5.2, 12-5 2
243 AN960PD-08 WASHER 9.5.2, 12-5 2
244 MS21042-08 NUT 9.5.2, 12-5 4
REVISION: A 02 NOV 00, B 29 DEC 03, C 05 APR 04, D 17 MAY 2004
PAGE NO NEXT PAGE
8 9

245 PNV10-1-3 "B" WARNING PLACARD 9.5.2, 12-1 1
246 PNV07-7-1 "B" WARNING CIRCUIT BREAKER 9.5.2, 12-1 1
247 PNV10-1-1 "A" WARNING PLACARD 9.5.2, 12-1 1
248 PNV07-7-1 "A" WARNING CIRCUIT BREAKER 9.5.2, 12-1 1
249 PNV10-1-2 "CARGO DOOR IN TRANSIT" PLACAR 9.5.2, 12-1 1
250 PNV07-7-1 "VENT AND CARGO DOOR IND" C/B 9.5.2, 12-1 1
251 PNV07-9-201 CABLE ASSEMBLY 9.5.2, 12-4 1
252 PNV07-9-203 CABLE ASSEMBLY 9.5.2, 12-4 1
253 PNV07-1-1 "A" WARNING LIGHT (W/CONNECTOR & PINS) 9.5.2, 12-2 1
254 PNV07-1-2 "B" WARNING LIGHT (W/CONNECTOR & PINS) 9.5.2, 12-2 1
255 PNV07-1-4 "IN TRANSIT" WARNING LIGHT (W/CONNECTOR & PINS) 9.5.2, 12-3 1
256 PNV07-1-3 "VENT DOOR" WARNING LIGHT (W/CONNECTOR & PINS) 9.5.2, 12-3 1
257 MS25281-R4 P-CLIP 9.5.2, 12-4 5
258 MS25281-R3 P-CLIP 9.5.2, 12-4 5
259 NAS1096-3-10 SCREW 9.5.2, 12-4 5
260 AN960-PD10 WASHER 9.5.2, 12-4 5
261 MS21042-3 NUT 9.5.2, 12-4 5
262 MS25281-R5 P-CLIP 9.5.2, 12-4 16
263 NAS1096-3-10 SCREW 9.5.2, 12-4 16
264 AN960PD-10 WASHER 9.5.2, 12-4 16
265 MS21042-3 NUT 9.5.2, 12-4 16
266 1151FRA5 FLEXIBLE SLEEVE 9.5.2, 12-4 255 ft.
267 MS35489-6 GROMMET 9.5.2, 12-4 7
268 ILB
269 NAS1033A3 NUT PLATE 9.5.2, 12-4 7
270 MS25281-R3 CLAMP 9.5.2, 12-4 3
271 NAS1096-3-10 SCREW 9.5.2, 12-4 3
272 AN960PD-10 WASHER 9.5.2, 12-4 3
273 MS21042-3 NUT 9.5.2, 12-4 3
274 MS25281-R2 CLAMP 9.5.2, 12-4 1
275 PNV11-3-19 BRACKET 9.5.2, 12-4(G) 1
276 AN525-10R7 SCREW 9.5.2, 12-4(G) 3
277 AN960PD-10 WASHER 9.5.2, 12-4(G) 3
278 MS21059-L3 ANCHOR NUT 9.5.2, 12-4(G) 3
279 MS3470W10-6P CONNECTOR 9.5.2, 12-4(G) 1
280 MS3470W10-6S CONNECTOR 9.5.2, 12-4(G) 1
281 MS3470W10-6PW CONNECTOR 9.5.2, 12-4(G) 1
282 MS3470W10-6SW CONNECTOR 9.5.2, 12-4(G) 1
283 ILB
284 PNV07-9-215 NUT PLATE 9.5.2, 12-4(G) 4
285 MS35206-215 SCREW 9.5.2, 12-4(G) 16
286 AN960PD-04L WASHER 9.5.2, 12-4(G) 16
287 PNV07-1-27 CONTROL PANEL PLATE 9.5.2, 12-3(B) 1
288 PNV07-1-29 CONTROL PANEL PLATE 9.5.2, 12-3(B) 1
289 MS35489-11 GROMMET 9.5.2, 12-6 3
I 290 MS35489-13 GROMMET 9.5.2, 12-6 7
291 PNV11-3-23 SWITCH BRACKET 2
292 PNV11-3-25 SWITCH ACTUATOR 2
293 MS27212-6-10 TERMINAL BLOCK 1
294 MS18029-6S10 COVER 1
REVISION: A 02 NOV 00, B 29 DEC 03, C 05 APR 04, D 17 MAY 2004, E 14 JUL 2004, F 01 SEPT 2004
PAGE NO NEXT PAGE
9 END
PACKING LIST DOCUMENT:

I 295 PNV07-9-1 WIRE PACKAGE 1
REVISION: F 01 SEPT 2004

150 END
ISSUED: 18 MAY 2000
APPENDIX G
HYDRAULIC SCHEMATIC
REVISION: “F”
REVISION: “C”
“B” 13
“G” 17
30
24 JANUARY
20 NOVEMBER
DECEMBER
MARCH
JUL 200520042003
2005
ISSUED:
END
18 MAY 2000
NOTES:
1. RELIEF VALVE SETTING ADJUSTED TO 2800 PSI ± 75 PSI.
REVISION: “F”
“G” 17 JANUARY
20 NOVEMBER
JUL 2003
2005 2005
ISSUED: 18 MAY 2000
DOCUMENT NAME: NATIONAL AIRCRAFT
B727 AIRCRAFT SERVICE INC.
NASI
National Aircraft Service Inc.
Tecumseh, MI 49286
PEMCO CARGO CONVERTED B-727 AIRCRAFT
MAIN DECK CARGO DOOR LOCKING/WARNING

AND VENT DOOR SYSTEM INSTALLATION MANUAL
PNV-727-12 (STC ST01270CH)
REVISION: “B” 17 NOVEMBER 2003

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DOCUMENT TABLE OF CONTENTS

DOCUMENT REVISIONS LOG 2

APPLICABILITY/APPROVALS & REQUIREMENT FOR INSTALLATION 3

RETURNING AIRCRAFT TO SERVICE 5

CHAPTER 1, INSTALLATION PREPARATION AND HARDWARE REMOVAL 6 thru 20

CHAPTER 2, MAIN CARGO DOOR LOCKING/WARNING SYSTEM INSTALLATION 21 thru 66

CHAPTER 3, VENT DOOR INSTALLATION PREPARATION AND AIRCRAFT MODIFICATIONS 67 thru 69

CHAPTER 4, VENT DOOR INSTALLATION 70 thru 74

CHAPTER 5, VENT DOOR EXTERNAL ACTUATING HANDLE ASSEMBLY INSTALLATION 75 thru 88

CHAPTER 6, CARGO DOOR GANG BAR BLOCKERS/CONTROL CABLE ASSEMBLY

CHAPTER 8, CARGO DOOR ELECTRIC SYSTEM INSTALLATION 114 thru 131

CHAPTER 10, INSTALLATION SIGN OFF LIST 138 thru 141

APPLICABLE DOCUMENT REVISIONS

REV. DATE DESCRIPTION APPROVAL/DATE

NC INITIAL RELEASE: PAGES 1 THROUGH 124

B 30 Dec 2003 Revised pages 1, 2, 5, 27-122

C 24 Mar 2004 Revised pages 1,2,4,7,8,10,12,14,15,16,20,22 thru 26,

This Installation Instructions Manual PNV-727-12 is applicable to Boeing Corporation aircraft

All Serial Numbers as applicable to Boeing B727

REQUIREMENT FOR INSTALLATION

Specific use of this document shall be as follows:

NATIONAL AIRCRAFT SERVICE INC. has authorized,

to use the data of STC No. ST01270CH issued on 07 July 2000,

to modify Boeing B727 aircraft model ________________,

Serial Number ____________________

All proprietary rights are reserved

READ THIS PAGE 4, ACKNOWLEDGE: DATE:

9.1 RETURNING AIRCRAFT TO SERVICE

After the installation is complete the following MUST BE ACCOMPLISHED:

(7) Transcribe applicable entry in the aircraft log look.

READ THIS PAGE 5, ACKNOWLEDGE: DATE:

9.2 EXISTING HARDWARE REMOVAL

a) Lock bar may be cut through as required to facilitate removal.

NOTE: All disconnected wiring which is

EXISTING HARDWARE REMOVAL

Ref: Fig. 1-2

FIGURE/ PART NUMBER NOMENCLATURE DISPOSITION UNITS

10 602EN602-6 MICRO SWITCH (S2A) (V91929) DISCARD 1

15 29-894-11 BRACKET (V91763) ATTACHING PARTS DISCARD 1

20 NAS517-3-4 SCREW DISCARD 3

25 AN960-10L WASHER DISCARD 3

30 MS21042-3 NUT DISCARD 3

EXISTING HARDWARE REMOVAL

EXISTING HARDWARE REMOVAL

Ref: Fig. 1-3

FIGURE/ PART NUMBER NOMENCLATURE DISPOSITION UNITS

10 602EN602-6 MICRO SWITCH (S17) (V91929) DISCARD 1

15 29-894-12 BRACKET (V91763) ATTACHING PARTS DISCARD 1

20 NAS517-3-4 SCREW DISCARD 3

25 AN960-10L WASHER DISCARD 3

30 MS21042-3 NUT DISCARD 3

EXISTING HARDWARE REMOVAL

EXISTING HARDWARE REMOVAL

Ref: Fig. 1-4

FIGURE/ PART NUMBER NOMENCLATURE DISPOSITION UNITS

10 602EN602-6 MICRO SWITCH (S17) (V91929) DISCARD 1

15 29-894-12 BRACKET (V91763) ATTACHING PARTS DISCARD 1

20 NAS517-3-4 SCREW DISCARD 3

25 AN960-10L WASHER DISCARD 3

30 MS21042-3 NUT DISCARD 3

35 29-894-19 PLATE ASSY-STRIKER (V91763) DISCARD 1