P.O.

BOX 3689 BRISTOL, TENNESSEE 37625-3689 USA

TELEPHONE: 423-538-5151 TOLL FREE: 800-251-7094
TELEFAX: 423-538-8469 E-MAIL: [email protected]
[email protected]

INSTRUCTIONS
for
CONTINUED AIRWORTHINESS
for
AUTOMATIC DOOR OPENER KITS
407-510-103 DOOR OPENER KIT
407-510-105 (5 DOOR) DOOR OPENER KIT
STC: SH1990SO.

FOR

BELL HELICOPTER TEXTRON MODEL 407 HELICOPTERS

Report Number AA-00129

Revision B

July 16, 2012

RESTRICTED DISCLOSURE NOTICE ON PAGE 2

BHT 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-00129
AUTOMATIC DOOR OPENER KITS Revision B

RESTRICTED DISCLOSURE NOTICE

THE DRAWINGS, SPECIFICATIONS, DESCRIPTIONS, AND OTHER

TECHNICAL DATA ATTACHED HERETO ARE PROPRIETARY AND
CONFIDENTIAL TO BELL HELICOPTER TEXTRON, INC. (BHTI) AND
CONSTITUTE TRADE SECRETS FOR PURPOSES OF THE TRADE
SECRET AND FREEDOM OF INFORMATION ACTS. NO DISCLOSURE
TO OTHERS, EITHER IN THE UNITED STATES OR ABROAD, OR
REPRODUCTION OF ANY PART OF THE INFORMATION SUPPLIED IS
TO BE MADE, AND NO MANUFACTURE, SALE OR USE OF ANY
INVENTION OR DISCOVERY DISCLOSED HEREIN SHALL BE MADE,
EXCEPT BY WRITTEN AUTHORIZATION OF BHTI. THIS NOTICE
WILL NOT OPERATE TO NULLIFY OR LIMIT RIGHTS GRANTED BY
CONTRACT. THE DATA SUBJECT TO THIS RESTRICTION IS
CONTAINED IN ALL SHEETS AND IS DISCLOSED TO PERSONNEL
OF BHTI, FOR THE PURPOSE(S) OF INTERNAL USE AND
DISTRIBUTION ONLY.

© (2012) BHTI
UNPUBLISHED - ALL RIGHTS RESERVED

AERONAUTICAL ACCESSORIES
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BHT 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-00129
AUTOMATIC DOOR OPENER KITS Revision B

LIST OF EFFECTIVE PAGES

All pages contained herein are at latest revision shown in Log of Revisions.
LIST OF EFFECTIVE PAGES 1 – 18

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BHT 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-00129
AUTOMATIC DOOR OPENER KITS Revision B

TABLE OF CONTENTS
Identification Title Page

1.0 INTRODUCTION ............................................................................................................. 7

1.1 DISTRIBUTION ............................................................................................................... 7
1.2 REVISION ....................................................................................................................... 7
2.0 DESCRIPTION ................................................................................................................ 7
3.0 MAINTENANCE INSTRUCTIONS................................................................................... 7
3.1 REPAIR ........................................................................................................................... 7
4.0 TROUBLE INFORMATION.............................................................................................. 8
5.0 REMOVAL AND REPLACEMENT INFORMATION......................................................... 9
5.1 REMOVAL - GAS CYLINDER ASSEMBLY ..................................................................... 9
5.2 INSTALLATION - GAS CYLINDER ASSEMBLY ............................................................. 9
5.3 REMOVAL – BALL STUD, CREW AND PASSENGER DOOR ....................................... 9
5.4 INSTALLATION – BALL STUD, CREW AND PASSENGER DOOR ............................... 9
5.5 REMOVAL – BALL STUD, BAGGAGE DOOR ................................................................ 9
5.6 INSTALLATION – BALL STUD, BAGGAGE DOOR ........................................................ 9
6.0 SPECIAL TOOLS NEEDED .......................................................................................... 10
7.0 RECOMMENDED OVERHAUL PERIODS .................................................................... 10
8.0 AIRWORTHINESS LIMITATIONS ................................................................................. 10
9.0 WEIGHT AND BALANCE .............................................................................................. 10
10.0 PART BREAKDOWN .................................................................................................... 11
11.0 REFERENCE INSTALLATION DRAWINGS ................................................................. 15

LIST OF TABLES
List of Tables Title Page

TABLE 1. TROUBLESHOOTING .............................................................................................. 8

TABLE 2. PART BREAKDOWN 407-510-103 / 407-510-105 / 407-510-203 /
407-510-205 DOOR OPENER KIT ........................................................................ 12
TABLE 3. PART BREAKDOWN 407-511-103 CREW DOOR OPENER KIT ......................... 12
TABLE 4. PART BREAKDOWN 407-511-101 (L/H) / 407-511-102 (R/H) CREW
DOOR OPENER KIT .............................................................................................. 12
TABLE 5. PART BREAKDOWN 407-512-103 PASSENGER DOOR OPENER KIT .............. 13
TABLE 6. PART BREAKDOWN 407-512-101 (L/H) / 407-512-102 (R/H) PASSENGER
DOOR OPENER KIT .............................................................................................. 13
TABLE 7. PART BREAKDOWN 206-510-214 BAGGAGE DOOR OPENER KIT .................. 13
TABLE 8. PART BREAKDOWN 407-592-003 (L/H) / (407-592-004 (R/H) CREW
DOOR OPENER KIT .............................................................................................. 14

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BHT 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-00129
AUTOMATIC DOOR OPENER KITS Revision B

LIST OF FIGURES
List of Figures Title Page

FIGURE 1. CREW DOOR DOOR OPENER INSTALLATION ................................................. 16

FIGURE 2. PASSENGER DOOR DOOR OPENER INSTALLATION...................................... 17
FIGURE 3. BAGGAGE DOOR DOOR OPENER INSTALLATION .......................................... 18

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BHT 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-00129
AUTOMATIC DOOR OPENER KITS Revision B

1.0 INTRODUCTION
These instructions contain the information necessary to inspect and maintain the
AERONAUTICAL ACCESSORIES AUTOMATIC DOOR OPENER KITS installed
on Bell Helicopter Textron (BHT) model 407 helicopters in accordance with STC
SH1990SO.

1.1 DISTRIBUTION
These instructions are provided with each model 407 Automatic Door Opener Kit.
Any airworthiness or flight safety revisions will be immediately made available to
all affected Automatic Door Opener Kit owners.

1.2 REVISION
A Log of Revisions section is included in these instructions and will be utilized to
document all changes. Change recommendations should be submitted to:
Aeronautical Accessories Bell Helicopter Piney Flats
P.O. Box 3689
Bristol, TN 37625-3689
Email: [email protected]

2.0 DESCRIPTION
The Aeronautical Accessories Automatic Door Openers provide automatic
cockpit, cabin and baggage door opening when the door latches are released.
The gas cylinders are equipped with a feature which controls the rate of opening
and prevents doors from traveling past normal open positions. Automatic Door
Openers provide easy entrance and exit of crew and passengers and help
prevent damage to doors and airframe due to rotorwash or sudden wind gusts.
The Baggage Door Opener holds the baggage door open to facilitate the loading
and unloading of luggage or cargo.

3.0 MAINTENANCE INSTRUCTIONS

Once installed, the Automatic Door Openers are maintenance free and there are
no periodic inspections requirements.

3.1 REPAIR
Repair actions are limited to Gas Cylinder Assembly and Ball Stud removal and
replacement. (Refer to paragraph 5.0 for procedures).

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AUTOMATIC DOOR OPENER KITS Revision B

4.0 TROUBLE INFORMATION

For troubleshooting information refer to Table 1.

TABLE 1. TROUBLESHOOTING

Problem Probable Cause Solution

Door does not open Gas Cylinder Assembly has Contact Aeronautical Accessories
automatically failed for replacement Gas Cylinder
Assembly
Door stuck in place Gas Cylinder Assembly has Contact Aeronautical Accessories
failed for replacement Gas Cylinder
Assembly
Gas Cylinder Safety Clip has failed Contact Aeronautical Accessories
Assembly detaches for replacement Safety Clip
from Ball Stud Gas Cylinder Assembly Ball Contact Aeronautical Accessories
Socket has failed for replacement Gas Cylinder
Assembly
Ball Stud is worn or broken Contact Aeronautical Accessories
for replacement Ball Stud

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BHT 407 INSTRUCTIONS for CONTINUED AIRWORTHINESS AA-00129
AUTOMATIC DOOR OPENER KITS Revision B

5.0 REMOVAL AND REPLACEMENT INFORMATION

Repair actions are limited to Gas Cylinder Assembly and Ball Stud removal and
replacement. (Refer to Tables 2 thru 8 and Figures 1 thru 3 for part identification.)

5.1 REMOVAL - GAS CYLINDER ASSEMBLY

1. Remove Gas Cylinder Assemblies by removing Safety Clips, then pull cylinder
off of Ball Studs.

5.2 INSTALLATION - GAS CYLINDER ASSEMBLY

1. Install the Gas Cylinder Assemblies by snapping cylinder sockets onto Ball
Studs and installing Safety Clips.

5.3 REMOVAL – BALL STUD, CREW AND PASSENGER DOOR

1. Remove Gas Cylinder Assembly by removing Safety Clips, then pull cylinder
off of Ball Studs.
2. Loosen and remove Ball Stud by turning counter-clockwise.

5.4 INSTALLATION – BALL STUD, CREW AND PASSENGER DOOR

1. Install Ball Stud by turning clockwise. Torque Ball Stud to 15 in-lbs.
2. Reinstall the Gas Cylinder Assembly by snapping cylinder sockets onto ball
studs and installing Safety Clips.

5.5 REMOVAL – BALL STUD, BAGGAGE DOOR

NOTE
Removal of a Baggage Door Opener Ball Stud is not
recommended unless Ball Stud is damaged. The Baggage
Door Opener Ball Stud is welded to its respective Doubler
Assembly.
1. Remove Gas Cylinder Assemblies by removing Safety Clips, then pull cylinder
off of Ball Studs.
1. For Door Doubler Assembly: Remove and retain the four (4) Screws and
Washers securing the Door Doubler Assembly to the Baggage Door.
2. For Bulkhead Doubler Assembly: Remove and retain the three (3) Screws and
Washers securing the Bulkhead Doubler Assembly to the compartment wall.

5.6 INSTALLATION – BALL STUD, BAGGAGE DOOR

NOTE
Obtain a new Doubler Assembly with a Door Opener Ball
Stud welded to it.
1. Install the removed Doubler Assembly using the associated retained
attachment hardware. Reinstall the Gas Cylinder Assembly by snapping
cylinder sockets onto ball studs and installing Safety Clips.

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AUTOMATIC DOOR OPENER KITS Revision B

6.0 SPECIAL TOOLS NEEDED

None

7.0 RECOMMENDED OVERHAUL PERIODS

No component overhaul required for this type design change.

8.0 AIRWORTHINESS LIMITATIONS

No airworthiness limitations associated with this type design change.
The Airworthiness Limitations section is FAA approved and specifies inspections
and other maintenance required under 14 CFR §§ 43.16 and 91.403, unless an
alternative program has been FAA approved.

9.0 WEIGHT AND BALANCE

Kit Weight Station Lateral Arm

Crew Door Openers 2.8 lbs 43.6 in 0.0 in
(both doors) (1.3 kg) (1107 mm) (0 mm)
Passenger Door Openers 2.8 lbs 103.9 in 0.0 in
(both doors) (1.3 kg) (2639 mm) (0 mm)
Baggage Door Opener 0.9 lbs 155.0 in -21.75 in
(0.4 kg) (3937 mm) (-552 mm)

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AUTOMATIC DOOR OPENER KITS Revision B

10.0 PART BREAKDOWN

Tables 2 thru 8 contain Part Breakdown data for the model 407 Automatic Door
Opener Kits.
The column Availability Code (AV Code) specifies the procurement status for
each part. The codes to identify if a part is procurable, procedure details to get
an assembly or local manufacture code are as follows:

AV
Details
Code
0 Nonprocurable part
1 Procurable part
2 Procure as detail parts only
3 Procurable as Next Higher Assembly
4 Local manufacture. Contact AA Product Support Engineering (PSE)
5 Part replacement requires a fixture or special equipment. Contact PSE
6 Non-stock procurable part

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AUTOMATIC DOOR OPENER KITS Revision B

TABLE 2. PART BREAKDOWN

407-510-103 / 407-510-105 / 407-510-203 / 407-510-205
DOOR OPENER KIT
Qty Qty Qty Qty AV
-103 -105 -203 -205
Part Number Description Code
1 1 407-511-103 Crew Door Opener Kit (2 door) 1
1 1 1 1 407-512-103 Passenger Door Opener Kit (2 door) 1
1 1 206-510-214 Baggage Door Opener Kit 1
1 1 407-592-003 Door Opener Kit, L/H 1
1 1 407-592-004 Door Opener Kit, R/H 1

TABLE 3. PART BREAKDOWN

407-511-103 CREW DOOR OPENER KIT
AV
Qty Part Number Description Code
1 407-511-101 Crew Door Opener Kit (L/H) 1
1 407-511-102 Crew Door Opener Kit (R/H) 1

TABLE 4. PART BREAKDOWN

407-511-101 (L/H) / 407-511-102 (R/H) CREW DOOR OPENER KIT
Qty Qty AV
-101 -102
Part Number Description Code
1 407-514-101 Sill Doubler Assembly 1
1 407-514-102 Sill Doubler Assembly 1
1 407-514-105 Crew Door Doubler Assembly 1
1 407-514-106 Crew Door Doubler Assembly 1
1 1 407-517-126 Sill Doubler Spacer 1
1 1 407-517-130 Template 1
4 4 206-513-203 Safety Clip 1
1 1 407-515-108 Gas Cylinder Assembly (Alt: 407-515-106) 1
2 2 206-514-005 Ball Stud 1
6 6 NAS1149F0532P Washer 1
6 6 NAS1149F0563P Washer 1
26 26 CR3523-4-2 Rivet (Alt: M7885/4-4-2) 1
4 4 CR3523-4-4 Rivet (Alt: M7885/4-4-4) 1
3 3 CR3523-4-5 Rivet (Alt: M7885/4-4-5) 1
8 8 CR3523-4-6 Rivet (Alt: M7885/4-4-6) 1
7 7 CR3523-4-7 Rivet (Alt: M7885/4-4-7) 1

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TABLE 5. PART BREAKDOWN

407-512-103 PASSENGER DOOR OPENER KIT
AV
Qty Part Number Description Code
1 407-512-101 Passenger Door Opener Kit (L/H) 1
1 407-512-102 Passenger Door Opener Kit (R/H) 1

TABLE 6. PART BREAKDOWN

407-512-101 (L/H) / 407-512-102 (R/H) PASSENGER DOOR OPENER KIT
Qty Qty AV
-101 -102
Part Number Description Code
1 407-515-121 Litter Door Bracket Assembly 1
1 407-515-107 Sill Bracket Assembly 1
1 407-515-113 Door Doubler Assembly 1
1 407-515-104 Door Doubler Assembly 1
4 4 206-513-203 Safety Clip 1
1 1 407-515-108 Gas Cylinder Assembly (Alt: 407-515-106) 1
1 407-518-144 Template 1
2 2 206-514-005 Ball Stud 1
3 MS27039C1-06 Screw 1
1 MS27039C1-09 Screw 1
2 2 MS27039C1-27 Screw 1
2 2 NAS1149C0332R Washer 1
2 2 NAS1149C1165R Washer 1
6 6 NAS1149F0532P Washer 1
6 6 NAS1149F0563P Washer 1
3 MS21209-F1-15 Helicoil (Alt: 3591-3CN-0285) 1
19 CR3523-4-2 Rivet (Alt: M7885/4-4-2) 1
21 CR3523-4-3 Rivet (Alt: M7885/4-4-3) 1
4 CR3523-4-4 Rivet (Alt: M7885/4-4-4) 1

TABLE 7. PART BREAKDOWN

206-510-214 BAGGAGE DOOR OPENER KIT
Qty AV
Part Number Description Code
1 206-517-101 Doubler Assembly 1
1 206-517-102 Doubler Assembly 1
4 206-513-203 Safety Clip 1
1 206-513-211 Gas Cylinder Assembly 1
4 D1836-3-08M Insert (Alt: NAS1836-3-08M) 1
3 80-004-2-6 Insert 1
3 MS27039-1-06 Screw 1
7 AN960-10 Washer (Alt: NAS1149F0363P) 1
1 099-050-121 Adhesive, Magnobond 6398 A & B 1
4 MS27039-1-05 Screw 1

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AUTOMATIC DOOR OPENER KITS Revision B

TABLE 8. PART BREAKDOWN

407-592-003 (L/H) / (407-592-004 (R/H) CREW DOOR OPENER KIT
Qty Qty AV
-003 -004
Part Number Description Code
1 1 407-592-121 Shim (2024-T3, .063 THK, AMS-QQ-A-250/4) 1
1 1 407-575-107 Door Doubler Assembly 1
1 1 407-575-115 Gas Cylinder Assembly 1
1 1 407-575-128 Sill Bracket 1
1 1 407-575-131 Ball Stud Spacer 1
4 4 NAS1149F0563P Washer 1
1 1 206-514-007 Ball Stud 1
1 1 206-514-141 Ball Stud 1
1 1 MS27039-5-11 Screw 1
12 12 CR3522-4-2 Rivet (Alt: M7885/5-4-2) 1
10 10 CR3523-4-3 Rivet (Alt: M7885/4-4-3) 1
4 4 CR3523-4-4 Rivet (Alt: M7885/4-4-4) 1
2 2 CR3523-4-5 Rivet (Alt: M7885/4-4-5) 1
12 12 CR3523-4-6 Rivet (Alt: M7885/4-4-6) 1
6 6 CR3523-4-7 Rivet (Alt: M7885/4-4-7) 1
1 407-514-101 Sill Doubler Assembly 1
1 407-514-102 Sill Doubler Assembly 1
4 4 206-513-203 Safety Clip 1
1 1 407-517-126 Spacer, Sill Doubler 1
1 1 099-050-177 Adhesive, Threadlocker (Loctite 26205 (.02 oz)) 1
1 1 099-050-121 Adhesive (Magnobond 6398 A&B (8 oz)) 1
1 1 AA-11047 Installation Instructions 1

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AUTOMATIC DOOR OPENER KITS Revision B

11.0 REFERENCE INSTALLATION DRAWINGS

Figures 1 thru 3 ARE NOT TO SCALE and are provided as reference parts
installation location and identification information for the model 407 Automatic
Door Opener Kits.
Contact:
Aeronautical Accessories
Attn: Customer Support
P.O. Box 3689
Bristol, TN 37625-3689
Email: [email protected]
for applicable engineering drawing information

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407-514-105 (L/H SHOWN)

CREW DOOR DOUBLER ASSEMBLY (407-511-101)
407-514-106 (R/H OPPOSITE)
CREW DOOR DOUBLER ASSEMBLY (407-511-102)
407-575-107
DOOR DOUBLER ASSEMBLY (407-592-003 / -004)

206-513-203
SAFETY CLIP
(1 EACH END)

407-515-108 GAS CYLINDER ASSEMBLY

(407-511-101 / -102)
407-575-115 GAS CYLINDER ASSEMBLY
(407-592-003 / -004)

407-514-101 (L/H SHOWN)

SILL DOUBLER ASSEMBLY
407-514-102 (R/H OPPOSITE)
SEAT (REF) SILL DOUBLER ASSEMBLY

FIGURE 1. CREW DOOR DOOR OPENER INSTALLATION

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AUTOMATIC DOOR OPENER KITS Revision B

407-515-104 R/H
DOOR DOUBLER ASSEMBLY

206-513-203 SAFETY CLIP

(1 EACH END)

FWD SEAT AFT SEAT

(REF) (REF)

407-515-108
GAS CYLINDER ASSEMBLY
407-515-107
SILL BRACKET ASSEMBLY

R/H PASSENGER DOOR KIT

407-515-113 L/H
DOOR DOUBLER ASSEMBLY

206-513-203 SAFETY CLIP

(1 EACH END)

AFT SEAT FWD SEAT

(REF) (REF)

407-515-108
GAS CYLINDER ASSEMBLY

407-515-121
LITTER DOOR BRACKET ASSEMBLY

L/H PASSENGER DOOR KIT

FIGURE 2. PASSENGER DOOR DOOR OPENER INSTALLATION

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AUTOMATIC DOOR OPENER KITS Revision B

206-517-102
DOUBLER ASSEMBLY

206-513-211
GAS CYLINDER ASSEMBLY

206-517-101 206-513-203
DOUBLER ASSEMBLY SAFETY CLIP
(1 EACH END)

FIGURE 3. BAGGAGE DOOR DOOR OPENER INSTALLATION

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