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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-52A0151 Original Issue: February 12, 2016 ATA System: 5234 SUBJECT: DOORS - Main Cargo Door - Cam Support Assembly Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). 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 © 2016 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
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, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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: February 12, 2016 727-52A0151 1 of 66
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 2 of 66 BOEING SERVICE BULLETIN 727-52A0151
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Table of Contents
S u m m a r y5
1. PLANNING INFORMATION9
A . E f f e c t i v i t y9
1. Airplanes9
2 . S p a r e s A f f e c t e d ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 1 E. Compliance .............................................. 1 1 F . A p p r o v a l ............................................... 1 2 G. Manpower .............................................. 1 3 H. Weight and Balance Changes .................................... 1 3 I. Electrical Load Data ......................................... 1 3 J . R e f e r e n c e s .............................................. 1 3
1. Existing Data: ......................................... 1 3
2. Data Supplied with this Service Bulletin: ........................... 1 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 4 K. Publications Affected ........................................ 1 4 L. Interchangeability and Intermixability of Parts ........................... 1 4 M. Software Accomplishment Summary ................................ 1 4
2. MATERIAL INFORMATION ........................................ 1 5 A. Material - Price and Availability ................................... 1 5 B. Industry Support Information .................................... 1 5 C. Parts Necessary for Each Airplane ................................. 1 5 1 . K i t s / P a r t s ............................................ 1 5
2. Parts and Materials Supplied by the Operator ........................ 1 9
3. Parts Modified and Reidentified ................................ 1 9
4. Parts Removed and Not Replaced .............................. 1 9 D. Parts Necessary to Change Spares ................................. 1 9 E. Special Tooling - Price and Availability ............................... 1 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1 A. GENERAL INFORMATION ..................................... 2 1 B. WORK INSTRUCTIONS ....................................... 2 2 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT ........ 2 4 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT ....... 3 6 FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT ......... 4 9 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY - INSPECTION ........................ 6 1 APPENDIX B: ADDITIONAL ACCESS .................................... 6 3 APPENDIX C: PART DEMAND INTENT ................................... 6 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 3 of 66 BOEING SERVICE BULLETIN 727-52A0151
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 4 of 66 BOEING SERVICE BULLETIN 727-52A0151
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Commercial Airplanes 727 Service Bulletin ALERT SummaryNumber: 727-52A0151Original Issue: February 12, 2016 ATA System: 5234 SUBJECT: DOORS - Main Cargo Door - Cam Support Assembly Inspection and Replacement
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 None.
BACKGROUND Boeing analysis of the main cargo door cam support assemblies, part numbers 69-23588-5 and 69-23588-6, indicated that the repeat High Frequency Eddy Current (HFEC) inspections given in service bulletin 727-52A0124 is not adequate to reliably detect cracks before two adjacent cam support assemblies could fail, which would reduce the structural integrity of the door. The main cargo door is on the upper left side of the forward fuselage between body stations 480 and 620. The door is hinged on its upper edge and opens outward to a canopy or a fully open position. The main cargo door has eight cam support assemblies along the bottom of the door that support the latch cams. The door latch cams engage with latch pins on the fuselage and hold the door closed.
The main cargo door cam support assemblies are subject to ground loads, flight loads, and cabin pressure loads. If the work in this service bulletin is not done, undetected cracks at adjacent support assembly part numbers 69-23588-5 and 69-23588-6, or replacement part numbers 69-23588-9 and 69-23588-10, could result in reduced structural integrity of the main cargo door and consequent rapid decompression of the airplane.
This service bulletin gives instructions to do a ultrasonic inspection on the main deck cargo door cam support assemblies, part numbers 69-23588-5 and 69-23588-6, and to replace the cam support if any damage is found.
Instructions are also given to repeat the Ultrasonic Inspection of the main cargo door cam support assembly at all locations where an affected part number is installed for any crack at the repeat intervals.
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., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 5 of 66
ReferenceAffectedPlanning Data 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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Do an Ultrasonic Inspection of the main cargo door cam support assembly, part numbers 69-23588-5 and 69-23588-6, grease fitting lug area at each location for any crack. If no crack is found, repeat the Ultrasonic Inspection of the main cargo door cam support assembly at all locations where an affected part number is installed for any crack at the repeat interval given in Paragraph 1.E., Compliance. If any crack is found, replace the cam support assembly pair at the affected location and repeat the Ultrasonic Inspection of the main cargo door cam support assembly at all locations where an affected part number is installed for any crack at the repeat interval given in Paragraph 1.E., Compliance.
NOTE: 69-23588-5 and 69-23588-6 are affected part numbers. 69-23588-9 and 69-23588-10 are also affected part numbers if cam support assembly pair is replaced.
EFFECTIVITY 727C/-100C/-200F Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
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 inspection and repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 6 of 66 BOEING SERVICE BULLETIN 727-52A0151
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BOEING SERVICE BULLETIN 727-52A0151
ALERT ALERT Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX C of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
DO AN INSPECTION OF THE
CAM SUPPORT ASSEMBLIES
FOR ANY CRACK Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING 727-52A0151 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 66
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 8 of 66 BOEING SERVICE BULLETIN 727-52A0151
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Commercial Airplanes 727 Service Bulletin ALERT Number: 727-52A0151 Original Issue: February 12, 2016 ATA System: 5234 SUBJECT: DOORS - Main Cargo Door - Cam Support Assembly Inspection and Replacement
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 This service bulletin is applicable to 727C/-100C/-200F airplanes in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D6-9825 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 727-100C, -200F and 727C airplanes with main deck cargo door cam support assemblies, part numbers 69-23588-5 and 69-23588-6, or 69-23588-9 and 69-23588-10, installed.
-1 Airplane Models:
727-100C, 727-200F, 727C GroupVariable Number 1E5001 - E5011 1E5031 - E5068 1E5101 - E5116 1E5141 - E5143 1E5161 - E5164 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 9 of 66
GroupVariable Number 1E5201 - E5203 1E5221 - E5245 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 None.
C. Reason Boeing analysis of the main cargo door cam support assemblies, part numbers 69-23588-5 and 69-23588-6, indicated that the repeat High Frequency Eddy Current (HFEC) inspections given in service bulletin 727-52A0124 is not adequate to reliably detect cracks before two adjacent cam support assemblies could fail, which would reduce the structural integrity of the door. The main cargo door is on the upper left side of the forward fuselage between body stations 480 and 620. The door is hinged on its upper edge and opens outward to a canopy or a fully open position. The main cargo door has eight cam support assemblies along the bottom of the door that support the latch cams. The door latch cams engage with latch pins on the fuselage and hold the door closed. The main cargo door cam support assemblies are subject to ground loads, flight loads, and cabin pressure loads. If the work in this service bulletin is not done, undetected cracks at adjacent support assembly part numbers 69-23588-5 and 69-23588-6, or replacement part numbers 69-23588-9 and 69-23588-10, could result in reduced structural integrity of the main cargo door and consequent rapid decompression of the airplane.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 10 of 66 BOEING SERVICE BULLETIN 727-52A0151
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This service bulletin gives instructions to do a ultrasonic inspection on the main deck cargo door cam support assemblies, part numbers 69-23588-5 and 69-23588-6, and to replace the cam support if any damage is found. Instructions are also given to repeat the Ultrasonic Inspection of the main cargo door cam support assembly at all locations where an affected part number is installed for any crack at the repeat intervals.
D. Description Do an Ultrasonic Inspection of the main cargo door cam support assembly, part numbers 69-23588-5 and 69-23588-6, grease fitting lug area at each location for any crack. If no crack is found, repeat the Ultrasonic Inspection of the main cargo door cam support assembly at all locations where an affected part number is installed for any crack at the repeat interval given in Paragraph 1.E., Compliance. If any crack is found, replace the cam support assembly pair at the affected location and repeat the Ultrasonic Inspection of the main cargo door cam support assembly at all locations where an affected part number is installed for any crack at the repeat interval given in Paragraph 1.E., Compliance.
NOTE: 69-23588-5 and 69-23588-6 are affected part numbers. 69-23588-9 and 69-23588-10 are also affected part numbers if cam support assembly pair is replaced.
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 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.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
A logic diagram showing compliance tasks and compliance times is included as an aid in APPENDIX A.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 11 of 66 BOEING SERVICE BULLETIN 727-52A0151
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Table 1: Main Cargo Door Cam Support Assembly - Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,771 flight cycles or 27 months after the original issue date of this service bulletin, whichever occurs later Before 18,000 total flight cycles Do an Ultrasonic Inspection of any affected main cargo door cam support assemblies for any crack.
(a) All airplanes 6,000 flight cycles or 10 years, whichever occurs first --Repeat the Ultrasonic Inspection of the main cargo door cam support assemblies at all locations where an affected part is installed for any crack. (a) CONDITION 1: NO
CRACK FOUND --Before further flight ACTION 1: Do PART 1:
MAIN CARGO DOOR
CAM SUPPORT ASSEM- BLY REPLACEMENT.
CONDITION 2: ANY
CRACK FOUND 6,000 flight cycles or 10 years, whichever occurs first --ACTION 2: Repeat the Ultrasonic Inspection of the main cargo door cam support assemblies at all locations where an affected part is installed for any crack. (a)
(a) 69-23588-5 and 69-23588-6 are affected part numbers. 69-23588-9 and 69-23588-10 are also affected part numbers, if installed in accordance with PART 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENT.
F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 12, 2016 727-52A0151 12 of 66 BOEING SERVICE BULLETIN 727-52A0151