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Commercial Airplanes 757 Service Bulletin ALERT Number: 757-52A0094 Original Issue: December 23, 2015 ATA System: 5232 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:

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: December 23, 2015 757-52A0094 1 of 65

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Original Issue: December 23, 2015 757-52A0094 2 of 65 BOEING SERVICE BULLETIN 757-52A0094

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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 0 E. Compliance .............................................. 1 1 F . A p p r o v a l ............................................... 1 1 G. Manpower .............................................. 1 2 H. Weight and Balance Changes .................................... 1 2 I. Electrical Load Data ......................................... 1 2 J . R e f e r e n c e s .............................................. 1 2

1. Existing Data: ......................................... 1 2

2. Data Supplied with this Service Bulletin: ........................... 1 3

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 3 K. Publications Affected ........................................ 1 3 L. Interchangeability and Intermixability of Parts ........................... 1 3 M. Software Accomplishment Summary ................................ 1 3

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 8

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 8 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY - INSPECTION ........................ 6 0 APPENDIX B: ADDITIONAL ACCESS .................................... 6 2 APPENDIX C: PART DEMAND INTENT ................................... 6 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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Original Issue: December 23, 2015 757-52A0094 4 of 65 BOEING SERVICE BULLETIN 757-52A0094

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Commercial Airplanes 757 Service Bulletin ALERT SummaryNumber: 757-52A0094Original Issue: December 23, 2015 ATA System: 5232 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 indicated that the existing maintenance program for the support assemblies 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 assemblies could result in reduced structural integrity of the main cargo door and consequent rapid decompression of the airplane.

Boeing Fleet Team Digest (FTD) 757 FTD 52-15001 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., Compliance and Paragraph

1.F., Approval YesAD 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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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ReferenceAffectedPlanning Data 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

1. Do an Ultrasonic Inspection of the main cargo door cam support assembly grease fitting lug area at each location for any crack.

a. If no crack is found, repeat the Ultrasonic Inspection of the main cargo door cam support assembly at each location for any crack at the repeat interval given in Paragraph 1.E., Compliance.

b. 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 each location for any crack at the repeat interval given in Paragraph 1.E., Compliance.

EFFECTIVITY 757-200, -200CB, -200PF Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).

COMPLIANCE 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.

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.

Original Issue: December 23, 2015 757-52A0094 6 of 65 BOEING SERVICE BULLETIN 757-52A0094

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BOEING SERVICE BULLETIN 757-52A0094

ALERT ALERT

DO AN INSPECTION OF THE

CAM SUPPORT ASSEMBLIES

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Original Issue: December 23, 2015 757-52A0094 8 of 65 BOEING SERVICE BULLETIN 757-52A0094

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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

DESCRIPTIONCONFIGURATIONGROUP 757-200, -200CB, -200PF airplanes.-1 Airplane Models:

757-200, 757-200CB, 757-200PF GroupVariable Number 1NA201 - NA204 1NA206 - NA213 1NA215 - NA236 1NC042 1NC901 - NC951 1NC971 - NC974 1ND895 1NE021 1NE301 1NS601 - NS616 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

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GroupVariable Number 1NT001 - NT009

2. Spares Affected None.

B. Concurrent Requirements None.

C. Reason Boeing analysis of the main cargo door cam support assemblies indicated that the existing maintenance program for the support assemblies 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 assemblies could result in reduced structural integrity of the main cargo door and consequent rapid decompression of the airplane.

Boeing Fleet Team Digest (FTD) 757 FTD 52-15001 is related to this service bulletin.

D. Description

1. Do an Ultrasonic Inspection of the main cargo door cam support assembly grease fitting lug area at each location for any crack.

a. If no crack is found, repeat the Ultrasonic Inspection of the main cargo door cam support assembly at each location for any crack at the repeat interval given in Paragraph 1.E., Compliance.

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

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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.

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.

Table 1: Main Cargo Door Cam Support Assembly - Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 2,743 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 the main cargo door cam support assembly at each location for any crack.

All airplanes 6,000 flight cycles--Repeat the Ultrasonic Inspection of the main cargo door cam support assembly at each location for any crack.

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--ACTION 2: Repeat the Ultrasonic Inspection of the main cargo door cam support assembly at each location for any crack.

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.

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G. Manpower The tables below show an estimate of the task hours necessary to do this inspection for each airplane and to replace each pair of cam latch support fittings. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Inspection Elapsed HoursTask HoursNumber of PersonsTask

1.501.501Preparation

2.502.501Inspect

1.501.501Restoration

5.505.50TOTAL FOR EACH AIRPLANE Replacement Elapsed HoursTask HoursNumber of PersonsTask 6122Open Access 16322FIGURE 1 16322FIGURE 2 16322FIGURE 3 8162Close Access 3060TOTAL FOR EACH CAM SUPPORT FIT-

TING PAIR H. Weight and Balance Changes None.

I. Electrical Load Data Not changed.

J. References

1. Existing Data:

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