Boeing ASB 727-52A0150: Revision 1, text

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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-52A0150 Original Issue: January 30, 2012 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: January 30, 2012 727-52A0150 1 of 76

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Original Issue: January 30, 2012 727-52A0150 2 of 76 BOEING SERVICE BULLETIN 727-52A0150

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Table of Contents

Summary5

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

2. Spares Affected ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 1 E. Compliance .............................................. 1 2 F. Approval ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 2 I. Electrical Load Data ......................................... 2 2 J. References .............................................. 2 3

1. Existing Data .......................................... 2 3

2. Data supplied with this Service Bulletin ............................ 2 3

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 3 K. Publications Affected ........................................ 2 3 L. Interchangeability and Intermixability of Parts ........................... 2 4

2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 5

1. Kits/Parts ............................................ 2 5

2. Parts and Materials Supplied by the Operator ........................ 2 5

3. Parts Modified and Reidentified ................................ 2 6

4. Parts Removed and Not Replaced .............................. 2 6 D. Parts Necessary to Change Spares ................................. 2 6 E. Special Tooling - Price and Availability ............................... 2 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 7

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 0 FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION ......... 3 5 FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT ..... 3 8 FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT ............ 4 0 FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION ........ 4 2 FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT ........... 4 4 FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT ................... 4 6 FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT .................... 4 8 FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION ........... 5 0 FIGURE 9: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION ......... 5 2 FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING ............. 5 4 FIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT . . 57 APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST ......................... 5 9

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Commercial Airplanes 727 Service Bulletin ALERT SummaryNumber: 727-52A0150Original Issue: January 30, 2012 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND Accomplishment of the inspections in this service bulletin will make sure the Main Cargo Door (MCD) cam latches are inspected for wear and the latch pins are inspected for migration. The inspections are necessary in order to find and replace worn cam latches, latch pins and latch pin attachment bolts. If not replaced, worn cam latches, latch pins and latch pin attachment bolts could lead to a failure of the cam latches and may result in a possible rapid decompression and potential separation of the main cargo door from the airplane.

Boeing has received one report from one 757 operator that the MCD forward most cam latch on the forward center cam latch pair (cam latch number 3) broke during flight. The 757 airplane with the reported broken cam latch had accumulated 20,000 flight hours and 9,500 flight cycles when the cam latch broke. The crew heard a loud noise coming from the MCD shortly after cruise. Upon landing, an inspection was performed and a cam latch was found broken. The broken cam latch mating latch pin was also found to have significant wear as evidenced by the loss of the plating on the surface that is normally in contact with the cam latch. The latch pin was also deformed approximately 0.05 inch in the area of the wear surface.

The 727 MCD is of similar design to the 757 MCD. Boeing has not received any reports of a broken cam latch on a 727 MCD.

The cause of the broken cam latch has been determined to be from a poorly rigged MCD. Although properly rigged per the original Aircraft Maintenance Manual (AMM) procedures, significant variation was allowed in the rigging dimensions. This variation can cause some of the latch pin/cam latch locations to have a significant preload placed on them during engagement and rotation of the cam latches during latching and unlatching operations. This preload is believed to have imparted a torque on the latch pin from the cam latch rotation during latching and unlatching operations. The torque transmitted to the latch pin is then believed to have caused the latch pin cross bolt to fail in shear. In addition, the cross bolt that attaches the latch pin had signs of corrosion on the fracture surfaces.

Original Issue: January 30, 2012 727-52A0150 5 of 76

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If the cross bolt fails, the latch pin could migrate either towards the cam latch or away from the cam latch. Latch pin migration towards the cam latch can cause significant interference with the mating cam latch leading to cam latch damage. In this case, the latch pin migrated into the cam latch and caused damage to the cam latch. The crack initiated at the damage site caused by the latch pin and then lead to the cam latch breaking. Latch pin migration away from the cam latch could cause disengagement from the cam latch, resulting in no load transfer between the cam latch and the mating latch pin and may not be noticed before critical conditions are exceeded.

Accomplishment of the work given in this service bulletin will make sure the cam latches, latch pins and latch pins cross bolts are inspected and replaced if wear is found. The MCD will also be re-rigged to the requirements for door flushness, cam latch/latch pin concentricity, latch pin fitting forward/aft gap and shim thickness.

Boeing Service Related Problem (SRP) 727-SRP-52-0088 is related to this service bulletin.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION Get access to the MCD. Do a detailed inspection of the cam latches and latch pins. Check the torque of the cross bolts in the latch pins. Measure the extension of the latch pins. Replace all alloy steel cross bolts through the latch pins with Corrosion Resistant Steel (CRES) cross bolts. Do a High Frequency Eddy Current (HFEC) or alternate magnetic particle inspection of cam latch 1 and cam latch 2 for signs of cracks. Replace any cracked or broken parts. Rig the MCD to the requirements for door flushness, cam latch/latch pin concentricity, latch pin fitting forward/aft gap and shim thickness. Do the latch mechanism adjustment test and post-rigging inspections in accordance with this service bulletin.

EFFECTIVITY 727-100C, 727-200F and 727C airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

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COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and modifications given in this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Operator Supplied Parts/Materials.

Refer to Paragraph 2.A., Material - Price and Availability

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BOEING SERVICE BULLETIN 727-52A0150

ALERT ALERT

MAIN CARGO DOORWAY

LOWER SILL

LATCH PIN DO A DETAILED INSPECTION OF THE CAM LATCHES AND LATCH PINS.

CHECK THE TORQUE OF THE CROSS BOLTS IN THE LATCH PINS.

MEASURE THE EXTENSION OF THE LATCH PINS.

REPLACE ALL THE ALLOY STEEL CROSS BOLTS THROUGH THE

LATCH PINS WITH CRES CROSS BOLTS

DO A HFEC OR MAGNETIC PARTICLE INSPECTION OF CAM LATCH 1 AND CAM LATCH 2 FOR SIGNS OF CRACKS

- RIG THE MCD IN ACCORDANCE WITH THE REQUIREMENTS FOR DOOR

FLUSHNESS, CAM LATCH/LATCH PIN CONCENTRICITY, LATCH PIN FITTING FORWARD/AFT GAP AND SHIM THICKNESS.

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THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

DESCRIPTIONCONFIGURATIONGROUP 727-100C, 727-200F and 727C airplanes with a Main Cargo Door.-1 Airplane Models:

727-100C, 727-200F, 727C GroupVariable Number 1E5001 - E5011 1E5031 - E5068 1E5101 - E5116 1E5141 - E5143 1E5161 - E5164 1E5201 - E5203 1E5221 - E5245

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GroupVariable Number 1E5251 - E5252 1E5271 - E5281 1E5301 - E5306 1E5351 - E5353 1E5381 - E5382 1E5401 - E5424 1E5426 - E5429 1E5433 1E5435 1E5451 - E5455 1E5481 - E5483 1E5501 - E5502 1QL501 - QL515

2. Spares Affected None.

B. Concurrent Requirements The service bulletin listed below must be done in accordance with FAA Airworthiness Directive AD 91-22-04. If the service bulletin below has not previously been accomplished as required by AD 91-22-04, then it must be accomplished before further flight.

DescriptionService BulletinCompany Latch Cam Replacement and Pressure Relief Door Hinge Fitting Replacement.

727-52-0142, Revision 02

(a) Boeing

(a) The modification given in Boeing Service Bulletin 727-52-0142, Revision 02 is necessary to comply with FAA Airworthiness Directive AD 91-22-04.

C. Reason Accomplishment of the inspections in this service bulletin will make sure the Main Cargo Door (MCD) cam latches are inspected for wear and the latch pins are inspected for migration. The inspections are necessary in order to find and replace worn cam latches, latch pins and latch pin attachment bolts. If not replaced, worn cam latches, latch pins and latch pin attachment bolts could lead to a failure of the cam latches and may result in a possible rapid decompression and potential separation of the main cargo door from the airplane.

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The 727 MCD is of similar design to the 757 MCD. Boeing has not received any reports of a broken cam latch on a 727 MCD.

Boeing Service Related Problem (SRP) 727-SRP-52-0088 is related to this service bulletin.

D. Description Get access to the MCD. Do a detailed inspection of the cam latches and latch pins. Check the torque of the cross bolts in the latch pins. Measure the extension of the latch pins. Replace all alloy steel cross bolts through the latch pins with Corrosion Resistant Steel (CRES) cross bolts. Do a High Frequency Eddy Current (HFEC) or alternate magnetic particle inspection of cam latch 1 and cam latch 2 for signs of cracks. Replace any cracked or broken parts. Rig the MCD to the requirements for door flushness, cam latch/latch pin concentricity, latch pin fitting forward/aft gap and shim thickness. Do the latch mechanism adjustment test and post-rigging inspections in accordance with this service bulletin.

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones ZoneModel 2-48727-100C, 727-200F, 727C

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E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door (MCD) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Within 150 days after the original issue date of this service bulletin.

Within 330 flight cycles after the original issue date of this service bulletin.

Do the following for all MCD cam latches and latch pins:

Do a detailed inspection of the cam latches and latch pins in accordance with Accomplishment Instruction 3.B.1.b.

All airplanes AND Torque the cross bolts in the latch pins in accordance with Accomplishment Instruction 3.B.1.c.

AND Measure the extension of the latch pins in accordance with Accomplishment Instruction 3.B.1.d.

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