# Boeing Alert Service Bulletin 757-52A0094: SB-757-52A0094--BOEING - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2016-9185; AD 2017-19-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Alert Service Bulletin 757-52A0094](https://openairdocs.org/service-documents/boeing/757-52a0094.md) - Title as filed: SB-757-52A0094--BOEING - Pages: 65 - PDF: https://openairdocs.org/files/sha256/42/f7/42f701892e63a361270f58b20a72e74d877a5c2af241cecabd6de179a818f2ea - Page: https://openairdocs.org/service-documents/boeing/757-52a0094/file/42f701892e63 ## Text Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N. ### Page 1 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: BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2015 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 Unpublished Work.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: December 23, 2015 757-52A0094 1 of 65 2.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 2 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT BLANK PAGE ### Page 3 Table of Contents S u m m a r y ...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A . E f f e c t i v i t y ................................................ 9 1. Airplanes ............................................. 9 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. Original Issue: December 23, 2015 757-52A0094 3 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 4 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT BLANK PAGE ### Page 5 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. Original Issue: December 23, 2015 757-52A0094 5 of 65 ### Page 6 ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Air- plane 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 6 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 7 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT DO AN INSPECTION OF THE CAM SUPPORT ASSEMBLIES FOR ANY CRACK 2438161 Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING 757-52A0094 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 65 ### Page 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 8 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT BLANK PAGE ### Page 9 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 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. Original Issue: December 23, 2015 757-52A0094 9 of 65 ### Page 10 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. 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. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 838757-200, 757-200CB, 757- 200PF Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 10 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 11 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 is- sue date of this service bulletin, whichever oc- curs later. Before 18,000 total flight cycles Do an Ultrasonic Inspec- tion of the main cargo door cam support assem- bly at each location for any crack. All airplanes 6,000 flight cycles--Repeat the Ultrasonic In- spection of the main car- go door cam support as- sembly 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 11 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 12 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: a. Boeing Service Letter 757-SL-00-013 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 12 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 13 b. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-01, 20-50-19 c. 757 Aircraft Maintenance Manual (AMM) 12-21-23, 52-32-00 d. 757 Corrosion Prevention Manual (CPM) 52-30-01 e. 757 Fleet Team Digest (FTD) 52-15001 f. 757 Non-Destructive Testing (NDT) Manual Part 4, 52-30-01 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: None. K. Publications Affected 1. Publications: Chapter-SectionPublication PART 4, 52-30-01757 Non-Destructive Testing Manual 2. Damage Tolerance Based Structural Inspections: Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin. L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts. M. Software Accomplishment Summary Not affected. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 13 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 14 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 14 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT BLANK PAGE ### Page 15 2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kit is subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the original issue date of this Ser- vice Bulletin (US Dollars) ROLT as of the original issue date of this Ser- vice Bulletin (Cal- endar Days) QTYDateNameKit Number $15,298.005255January 26, 2016 TOP KIT - RETROFIT KIT FOR MAIN DECK CARGO DOOR 012N8972-1 $15,298.005253May 18, 2016TOP KIT - RETROFIT KIT FOR MAIN DECK CARGO DOOR 012N8972-1 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. B. Industry Support Information Boeing warranty remedies are not available for the inspection and repair procedures given in this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability. NOTE: Up to four (4) top kits are necessary for each airplane based on inspection findings. Top kit is configured for the replacement of any single pair of cam support assemblies. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 15 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 16 Kit 012N8972 NotesExisting Part Number NameQtyNew Part Number -1 (a)-TOP KIT - RETROFIT KIT FOR MAIN DECK CARGO DOOR -012N8972-1 (c)-CAM SUPPORT ASSEMBLY 169-23588U10 (c)-CAM SUPPORT ASSEMBLY 169-23588U9 (b)-bolt6BACB30LM3-4X (b)-BOLT9BACB30LM3-6X (b)-BOLT2BACB30LM3-8X (b)-BOLT3BACB30LM4-4X (b)-BOLT6BACB30LM4-6X (b)-BOLT2BACB30LM4-7X (b)-BOLT2BACB30LM4-8X (b)-BOLT2BACB30LM4-9X (b)-BOLT, PROTRUD- ING HD 4BACB30MY10K10X (b)-BOLT, PROTRUD- ING HD 4BACB30MY10K11X (b)-BOLT, PROTRUD- ING HD 2BACB30MY10K13X (b)-BOLT, PROTRUD- ING HD 1BACB30MY10K14X (b)-BOLT, PROTRUD- ING HD 2BACB30MY10K15X (b)-BOLT, PROTRUD- ING HD 1BACB30MY10K16X (b)-BOLT, PROTRUD- ING HD 1BACB30MY10K17X (b)-BOLT, PROTRUD- ING HD 2BACB30MY10K18X (b)-BOLT, PROTRUD- ING HD 2BACB30MY10K20X (b)-BOLT, PROTRUD- ING HD 3BACB30MY10K21X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 16 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 17 Kit 012N8972 NotesExisting Part Number NameQtyNew Part Number -1 (b)-BOLT, PROTRUD- ING HD 2BACB30MY10K22X (b)-BOLT, PROTRUD- ING HD 2BACB30MY10K23X (b)BOLT, PROTRUD- ING HD 12BACB30MY10K5X (b)-BOLT, PROTRUD- ING HD 4BACB30MY10K6X (b)-BOLT, PROTRUD- ING HD 2BACB30MY10K7X (b)-BOLT, PROTRUD- ING HD 4BACB30MY10K9X (b)-BOLT, PROTRUD- ING HD 1BACB30MY12K10X (b)-BOLT, PROTRUD- ING HD 4BACB30MY8K5X (b)-BOLT, PROTRUD- ING HD 5BACB30MY8K7X (b)-BOLT, 100 DEG HEX DR 1BACB30NW10K14X (b)-BOLT, 100 DEG HEX DR 1BACB30NW10K15X (b)-BOLT, 100 DEG HEX DR 1BACB30NW10K6X (b)-BOLT, 100 DEG HEX DR 1BACB30NW10K7X (b)-BOLT, 100 DEG HEX DR 2BACB30NW8K5X (b)-BOLT, 100 DEG HEX DR 2BACB30NW8K7X (b)-BOLT, PROTRUD- ING HD 5BACB30NX6K3X (b)-BOLT, PROTRUD- ING HD 6BACB30NX6K4X (b)-BOLT, PROTRUD- ING HD 1BACB30NX6K5X (b)-BOLT, PROTRUD- ING HD 1BACB30NX6K6X Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 17 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 18 Kit 012N8972 NotesExisting Part Number NameQtyNew Part Number -1 --COLLAR ASSEM- BLY 12BACC30AG10 --COLLAR20BACC30M10 --COLLAR1BACC30M12 --COLLAR7BACC30M6 --COLLAR13BACC30M8 --NUT16BACN10JC3CD --NUT,SELF-LOCK- ING 14BACN10JC4CD --RIVET, UNIVER- SAL HD 25BACR15BB6D7C --RIVET, 100 DEG4BACR15GF8D14 --WASHER, OVER- SIZE 16BACW10AW3AS --WASHER, OVER- SIZE 14BACW10AW4AS (a) There are more parts than are necessary. (b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits. (c) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the 'dash' configuration when installed as given in the Accom- plishment Instructions of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Boeing Service Letter 757- SL-00-013 for more information. 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 18 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 19 NotesNameQTYPart Number / Specification Refer to FIGURE 1, FIG- URE 2, and FIGURE 3. Op- tional to make in one piece rather than 4. RADIUS FILLER0.75 INCH X 0.75 INCH X 0.125 INCH 2024-T3 ALCLAD, 2024-T4 ALCLAD, or 7075-T6 AL- CLAD (a)SEALANT - PRESSURE AND ENVI- RONMENTAL - CHROMATE TYPE -BMS 5-95 (a)COATING - CHEMICAL AND SOL- VENT RESISTANT FINISH, CORRO- SION INHIBITING PRIMER -BMS 10-11, TYPE I (a)COATING - CHEMICAL AND SOL- VENT RESISTANT FINISH - BAC 702 WHITE COLOR, GLOSS -BMS 10-11, TYPE II (a)COATING - ORGANIC CORRO- SION INHIBITING COMPOUND -BMS 3-23, TYPE II (a)GREASE - AIRCRAFT GENERAL PURPOSE -BMS 3-33 (a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. No special parts or materials are necessary to do the change in this service bulletin. But, parts and materials in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available. 3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. D. Parts Necessary to Change Spares None. E. Special Tooling - Price and Availability None. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 19 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 20 F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 20 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 21 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. Unless shown differently, these dimensions and tolerances are used: – Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values: — Values for structural fasteners are given in 757 Structural Repair Manual, Chapter 51. — Values for airframe maintenance tasks are included in Chapter 20 of 757 Aircraft Maintenance Manual (AMM). — Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM). — Values for engine maintenance tasks are included in Chapter 70 of 757 Aircraft Maintenance Manual (AMM). — Non-standard torque values for maintenance tasks are included in the applicable installation step. 4. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51. 5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin. 6. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 21 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 22 7. Refer to APPENDIX A for the logic diagram. The logic diagram is provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., WORK INSTRUCTIONS is the primary source for tasks required for compliance. 8. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 9. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 10. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. 11. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. 12. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data. 13. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200. 14. 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. 15. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. 16. Some steps in the Work Instructions are labeled as Required for Compliance (RC). If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps labeled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including sub-steps and identified figures. Steps not labeled as RC may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC. This is provided that the RC steps, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition. B. WORK INSTRUCTIONS 1. Open the main cargo door. Refer to 757 AMM 52-32-00 for an accepted procedure. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 22 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 23 2. RC - Do an Ultrasonic Inspection of the main cargo door cam support assembly at each location for any crack in accordance with 757 NDT Manual Part 4, 52-30-01. a. CONDITION 1: NO CRACK FOUND (1) Repeat the Ultrasonic Inspection of the main cargo door cam support assembly at each location for any crack in accordance with 757 NDT Manual Part 4, 52-30-01 at the repeat interval given in Paragraph 1.E., Compliance. b. CONDITION 2: ANY CRACK FOUND (1) Do PART 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENT. (2) Repeat the Ultrasonic Inspection of the main cargo door cam support assembly at each location for any crack in accordance with 757 NDT Manual Part 4, 52-30-01 at the repeat interval given in Paragraph 1.E., Compliance. 3. Do an operational test of the main cargo door and check all affected hydraulic tubing and hoses for leakage. Refer to 757 AMM 52-32-00 for an accepted procedure. 4. Put the airplane back to a serviceable condition. PART 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENT 1. Replace the main cargo door cam support assembly pair at the affected locations as follows: NOTE: Refer to APPENDIX B for additional access. a. Replace the cam support assembly at stations 487.10 and 500 in accordance with FIGURE 1. b. Replace the cam support assembly at stations 520 and 540 in accordance with FIGURE 2. c. Replace the cam support assembly at stations 560 and 580 in accordance with FIGURE 2. d. Replace the cam support assembly at stations 600 and 612.9 in accordance with FIGURE 3. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 23 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 24 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT INBD 2442011 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 1 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 757-52A0094 Work - See page 1 for details. 24 of 65 ### Page 25 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 487.10 CAM SUPPORT ASSEMBLY 4U 16 LOCATIONS SUPPORT ASSEMBLY 0001 D D 14 15 18 BRACKET 6 LOCATIONS (12) 13 8 18 ® (4 LOCATIONS) LA TENSION 10U118 TIE CLIP > PART PROFILE SHOWN IS REFERENCE ONLY 2442012 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 2 OF 12) Original Issue: December 23, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-52A0094 Work - See page 1 for details. 25 of 65 ### Page 26 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 520 3€G80ULD18 WEB STA CAM SUPPORT 500 ASSEMBLY DU 16 LOCATIONS (16 17) 10 LOCATIONS 13) RADIUS FILLE / 14 LOCATIONS BRACKET 1001 12 14) 6 LOCATIONS X17 TENSION TIE CLIP 191118 9 11 14 15 18 SHEAR WEB CAM AND BELLCRANK ASSEMBLY 2443813 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 3 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 65 ### Page 27 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT CAM SUPPORT ASSEMBLY CAM SUPPORT ASSEMBLY STA 487.10 SHEAR WEB ··*··* TENSION TIE CLIP B-B - BRACKET SHEAR WEB B TENSION TIE CLIP A-A FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 4 OF 12) Original Issue: December 23, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-52A0094 Work - See page 1 for details. 27 of 65 ### Page 28 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 500 CAM SUPPORT SHEAR WEB CAM SUPPORT AlE ASSEMBLY BRACKET SHEAR WEB TENSION TIE CLIP C-C TENSION TIE CLIP D-D 2443875 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 5 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 65 ### Page 29 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT CAM SUPPORT ASSEMBLY STA 487.10 CAM SUPPORT ASSEMBLY SHEAR WEB STA 500 E-E 487.10 STA 2450368 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 6 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 65 ### Page 30 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane. More DataQtyIdentificationNameTaskStep -1-WEBRemove / Keep1 1-CAM AND BELL- CRANK ASSEMBLY Keep spacers.2-TENSION TIE CLIP -1-SHEAR WEB 2-BRACKET 1-SUPPORT ASSEMBLY Keep cam support assembly at STA 500 for use as an aid during alignment of new cam support assembly. 2-CAM SUPPORT AS- SEMBLY Remove Temporary install using existing holes to maintain original position. 1-CAM SUPPORT AS- SEMBLY Install (Kept)2 -169-23588U9CAM SUPPORT AS- SEMBLY Put / Hold (New)3 1-BRACKETPut / Hold (Kept) (a)1-SUPPORT ASSEMBLY -1-CAM AND BELL- CRANK ASSEMBLY Install (Temporary) Pick up existing holes. -69-23588U9CAM SUPPORT AS- SEMBLY Drill4 --BRACKET Pick up existing holes. (a) --SUPPORT ASSEMBLY -1-CAM AND BELL- CRANK ASSEMBLY Remove / Keep5 1-CAM SUPPORT AS- SEMBLY Remove (Kept) FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 7 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 30 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 31 More DataQtyIdentificationNameTaskStep -169-23588U10CAM SUPPORT AS- SEMBLY Put / Hold (New)6 1-BRACKETPut / Hold (Kept) 1-CAM AND BELL- CRANK ASSEMBLY Install (Temporary) Pick up existing holes. -69-23588U10CAM SUPPORT AS- SEMBLY Drill7 --BRACKET -1-CAM AND BELL- CRANK ASSEMBLY Remove / Keep8 169-23588U9CAM SUPPORT AS- SEMBLY 169-23588U10CAM SUPPORT AS- SEMBLY 2-BRACKET 1-SUPPORT ASSEMBLY -169-23588U9CAM SUPPORT AS- SEMBLY Install (Temporary)9 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP Pick up existing holes in shear web and tension tie clip. -69-23588U9CAM SUPPORT AS- SEMBLY Drill (Kept)10 -69-23588U10CAM SUPPORT AS- SEMBLY --SHEAR WEB --TENSION TIE CLIP -169-23588U9CAM SUPPORT AS- SEMBLY Remove / Keep11 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Keep spacers.2-TENSION TIE CLIP FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 8 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 31 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 32 More DataQtyIdentificationNameTaskStep (b)-69-23588U9CAM SUPPORT AS- SEMBLY Drill (Kept)12 -69-23588U10CAM SUPPORT AS- SEMBLY --SHEAR WEB ----Clean/Deburr (c)8-RADIUS FILLERMake13 Bench work. Install radius fillers at 3 lo- cations on each cam support assembly. 169-23588U9CAM SUPPORT AS- SEMBLY Assemble14 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Assembled cam support assemblies and shear web. 169-23588U9CAM SUPPORT AS- SEMBLY Put / Hold15 69-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP ---SHEAR WEBDrill16 ----Clean/Deburr17 (d) (e)169-23588U9CAM SUPPORT AS- SEMBLY Install (Kept)18 169-23588U10CAM SUPPORT AS- SEMBLY -2-BRACKET 1-SUPPORT ASSEMBLY Install radius fillers at remaining loca- tions. 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP Refer to CMM 52- 32-03 for an accept- ed procedure. 1-CAM AND BELL- CRANK ASSEMBLY FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 9 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 32 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 33 More DataQtyIdentificationNameTaskStep Fay and fillet seal with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted proce- dure. 1-WEBInstall (Kept)19 Refer to 757 AMM 12-21-23 for an ac- cepted procedure. -BMS 3-33GREASEApply20 (a) The door hook mechanism can be used as an aid to position the support assembly. Additional put/hold and drilling tasks may be necessary for the support assembly and are as required. (b) Bench work. Temporary assemble through holes common to the tension tie clip. Maintain the main cargo door frame-to-frame mounting surface distance between the cam support assemblies during drilling. (c) Make from 2024-T3 alclad, 2024-T4 alclad, or 7075-T6 alclad aluminum. Approximately 0.75 inch square by 0.125 inch thick. Optional to make in one piece rather than 4. Radius bottom of filler to fit curvature of fitting (0.010 inch maximum gap prior to fastener installation. Apply chemical conversion coating Type 1 or Type 2, Class A or C. Refer to SOPM 20-43-03 as an accepted procedure. Apply two coats of BMS 10-11, Type I primer. Refer to SOPM 20-41-02 for an accepted procedure. (d) Apply one layer of BMS 10-11, Type II enamel, color BAC 702 white gloss below door lower frame, except in cam latch bores, prior to installation of cam and bellcrank assembly. Refer to SOPM 20-41-02 for an accepted procedure. (e) Apply BMS 3-23, Type II corrosion inhibiting compound above and below door lower frame, except in cam latch bores, prior to installation of cam and bellcrank assembly. Refer to 757 CPM 52-30-01 and SOPM 20-41-05 for an accepted procedure. FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 10 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 33 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 34 The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure. More DataHole DiaQtyIdentificationNameCode (a)0.325-0.32818BACB30MY10K( )XBOLT, PROTRUDING HD A -0.325-0.32818BACC30M10COLLAR (a)0.325-0.3281BACB30NW10K6XBOLT, 100 DEG HEX DR B -0.325-0.3281BACC30M10COLLAR (a)0.388-0.3911BACB30MY12K10XBOLT, PROTRUDING HD C -0.388-0.3911BACC30M12COLLAR (a)0.2651-0.26618BACB30MY8K( )XBOLT, PROTRUDING HD D -0.2651-0.26618BACC30M8COLLAR (a)0.2651-0.26614BACB30LM4-( )XBOLTE -0.2651-0.26614BACW10AW4ASWASHER, OVERSIZE -0.2651-0.26614BACN10JC4CDNUT,SELF-LOCKING (a)0.2651-0.26614BACB30NW8K( )XBOLT, 100 DEG HEX DR F -0.2651-0.26614BACC30M8COLLAR --4BACR15GF8D14RIVET, 100 DEGG (a) (b)0.2651-0.266110BACB30LM4-( )XBOLTH (b)0.2651-0.266110BACW10AW4ASWASHER, OVERSIZE (b)0.2651-0.266110BACN10JC4CDNUT,SELF-LOCKING (a) (b)0.263-0.2661BACB30MY8K7XBOLT, PROTRUDING HD I (b)0.263-0.2661BACC30M8COLLAR (a)0.200-0.2032BACB30NX6K( )XBOLT, PROTRUDING HD J -0.200-0.2032BACC30M6COLLAR (a)0.200-0.2035BACB30NX6K3XBOLT, PROTRUDING HD K 0.200-0.2035BACC30M6COLLAR FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 11 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 34 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 35 More DataHole DiaQtyIdentificationNameCode --25BACR15BB6D7CRIVET, UNIVERSAL HD L (a)0.325-0.32811BACB30MY10K( )XBOLT, PROTRUDING HD M -0.325-0.32811BACC30AG10COLLAR ASSEMBLY (a)0.325-0.3281BACB30NW10K14XBOLT, 100 DEG HEX DR N -0.325-0.3281BACC30AG10COLLAR ASSEMBLY Pick up existing hole in the pressure door hinge structure. Use the existing fastener. 0.250-0.254---O (a) Install wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted procedure. (b) Touch up bolt head, washer/nut, or collar, as applicable, below door lower frame with BMS 10-11, Type I primer and BMS 10-11 Type II enamel, color BAC 702 white gloss. Refer to SOPM 20-41-02 for an ac- cepted procedure. FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 12 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 35 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 36 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT INBD 2438858 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 1 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING 757-52A0094 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 65 ### Page 37 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT 911 1 18 STA 500 OR STA 540 STA 520 OR WEB STA 560 CAM SUPPORT ASSEMBLY 500/520 ONLY STA TAS 1 19 16 LOCATIONS (4 (4 LOCATIONS) RADIUS FILLER 13 BRACKET 6 LOCATIONS 12) 14 8 18 11 TENSION TIE CLIP * 000B® 2442406 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 2 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING 151-52A0094 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 65 ### Page 38 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 560 OR STA 600 3€080UUD18 STA 540 OR CAM SUPPORT STA 580 ASSEMBLY DU 16 LOCATIONS (16 17) 10 LOCATIONS WEB STA 13) RADIUS FILLE 580/600 BRACKET / 14 LOCATIONS ONLY 12 14) 6 LOCATIONS 117 TENSION TIE CLIP 10U118 (15 18 SHEAR WEB ASSEMBLY CAM AND BELLCRANK 2444051 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 3 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING 757-52A0094 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 65 ### Page 39 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT CAM SUPPORT ASSEMBLY STA 520 ASSEMBLY CAM SUPPORT STA 560 OR SHEAR WEB **** * + 7 B-B TIE CLIP + STA 520 ONLY G STA 560 ONLY SHEAR WEB TENSION TIE CLIP A-A 2442430 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 4 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING 151-52A0094 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 65 ### Page 40 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 540 OR STA 580 CAM SUPPORT ASSEMBLY G- STA 540 ONLY - STA 580 ONLY SHEAR WEB CAM SUPPORT ASSEMBLY ALE BRACKET SHEAR WEB TENSION TENSION TIE CLIP TIE CLIP D-D C-C 2444052 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 5 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 757-52A0094 Work - See page 1 for details. 40 of 65 ### Page 41 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 520 STA 580 INBD CAM SUPPORT CAM SUPPORT ASSEMBLY ASSEMBLY SHEAR WEB STA STA 540 520 E-E 2450376 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 6 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 99 10 1 ### Page 42 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT CAM SUPPORT CAM SUPPORT ASSEMBLY ASSEMBLY SHEAR WEB STA STA 580 560 [FWD F-F 2461684 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 7 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING 757-52A0094 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 65 ### Page 43 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane. More DataQtyIdentificationNameTaskStep -1-WEBRemove / Keep1 1-CAM AND BELL- CRANK ASSEMBLY Keep spacers.2-TENSION TIE CLIP -1-SHEAR WEB 2-BRACKET Keep cam support assembly at STA 540 or STA 580 for use as an aid during alignment of new cam support assem- bly. 2-CAM SUPPORT AS- SEMBLY Remove Temporary install using existing holes to maintain original position. 1-CAM SUPPORT AS- SEMBLY Install (Kept)2 -169-23588U9CAM SUPPORT AS- SEMBLY Put / Hold (New)3 1-BRACKETPut / Hold (Kept) -1-CAM AND BELL- CRANK ASSEMBLY Install (Temporary) Pick up existing holes. -69-23588U9CAM SUPPORT AS- SEMBLY Drill4 --BRACKET -1-CAM AND BELL- CRANK ASSEMBLY Remove / Keep5 1-CAM SUPPORT AS- SEMBLY Remove (Kept) -169-23588U10CAM SUPPORT AS- SEMBLY Put / Hold (New)6 1-BRACKETPut / Hold (Kept) 1-CAM AND BELL- CRANK ASSEMBLY Install (Temporary) FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 8 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 43 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 44 More DataQtyIdentificationNameTaskStep Pick up existing holes. -69-23588U10CAM SUPPORT AS- SEMBLY Drill7 --BRACKET -1-CAM AND BELL- CRANK ASSEMBLY Remove / Keep8 169-23588U9CAM SUPPORT AS- SEMBLY 169-23588U10CAM SUPPORT AS- SEMBLY 2-BRACKET -169-23588U9CAM SUPPORT AS- SEMBLY Install (Temporary)9 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP Pick up existing holes in shear web and tension tie clip. -69-23588U9CAM SUPPORT AS- SEMBLY Drill (Kept)10 -69-23588U10CAM SUPPORT AS- SEMBLY --SHEAR WEB --TENSION TIE CLIP -169-23588U9CAM SUPPORT AS- SEMBLY Remove / Keep11 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Keep spacers.2-TENSION TIE CLIP (a)-69-23588U9CAM SUPPORT AS- SEMBLY Drill (Kept)12 -69-23588U10CAM SUPPORT AS- SEMBLY --SHEAR WEB ----Clean/Deburr (b)8-RADIUS FILLERMake13 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 9 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 44 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 45 More DataQtyIdentificationNameTaskStep Bench work. Install radius fillers at 3 lo- cations on each cam support assembly. 169-23588U9CAM SUPPORT AS- SEMBLY Assemble14 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Assembled cam support assemblies and shear web. 169-23588U9CAM SUPPORT AS- SEMBLY Put / Hold15 69-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP ---SHEAR WEBDrill16 ----Clean/Deburr17 (c) (d)169-23588U9CAM SUPPORT AS- SEMBLY Install (Kept)18 169-23588U10CAM SUPPORT AS- SEMBLY -2-BRACKET Install radius fillers at remaining loca- tions. 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP Refer to CMM 52- 32-03 for an accept- ed procedure. 1-CAM AND BELL- CRANK ASSEMBLY Fay and fillet seal with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted proce- dure. 1-WEBInstall (Kept)19 Refer to 757 AMM 12-21-23 for an ac- cepted procedure. -BMS 3-33GREASEApply20 (a) Bench work. Temporary assemble through holes common to the tension tie clip. Maintain the main cargo door frame-to-frame mounting surface distance between the cam support assemblies during drilling. FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 10 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 45 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 46 More DataQtyIdentificationNameTaskStep (b) Make from 2024-T3 alclad, 2024-T4 alclad, or 7075-T6 alclad aluminum. Approximately 0.75 inch square by 0.125 inch thick. Optional to make in one piece rather than 4. Radius bottom of filler to fit curvature of fitting (0.010 inch maximum gap prior to fastener installation. Apply chemical conversion coating Type 1 or Type 2, Class A or C. Refer to SOPM 20-43-03 as an accepted procedure. Apply two coats of BMS 10-11, Type I primer. Refer to SOPM 20-41-02 for an accepted procedure. (c) Apply one layer of BMS 10-11, Type II enamel, color BAC 702 white gloss below door lower frame, except in cam latch bores, prior to installation of cam and bellcrank assembly. Refer to SOPM 20-41-02 for an accepted procedure. (d) Apply BMS 3-23, Type II corrosion inhibiting compound above and below door lower frame, except in cam latch bores, prior to installation of cam and bellcrank assembly. Refer to 757 CPM 52-30-01 and SOPM 20-41-05 for an accepted procedure. The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure. More DataHole DiaQtyIdentificationNameCode (a)0.325-0.32820BACB30MY10K( )XBOLT, PROTRUDING HD A -0.325-0.32820BACC30M10COLLAR (a)0.2651-0.26618BACB30MY8K( )XBOLT, PROTRUDING HD B -0.2651-0.26618BACC30M8COLLAR (a)0.2651-0.26614BACB30LM4-( )XBOLTC -0.2651-0.26614BACW10AW4ASWASHER, OVERSIZE -0.2651-0.26614BACN10JC4CDNUT,SELF-LOCKING (a)0.2651-0.26614BACB30NW8K( )XBOLT, 100 DEG HEX DR D -0.2651-0.26614BACC30M8COLLAR FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 11 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 46 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 47 More DataHole DiaQtyIdentificationNameCode --4BACR15GF8D14RIVET, 100 DEGE (a) (b)0.2026-0.203616BACB30LM3-( )XBOLTF (b)0.2026-0.203616BACW10AW3ASWASHER, OVERSIZE (b)0.2026-0.203616BACN10JC3CDNUT (a) (b)0.263-0.2661BACB30MY8K7XBOLT, PROTRUDING HD G (b)0.263-0.2661BACC30M8COLLAR (a)0.325-0.32812BACB30MY10K( )XBOLT, PROTRUDING HD H (a)0.325-0.32812BACC30AG10COLLAR ASSEMBLY Pick up existing hole in the pressure door hinge structure. Use the existing fastener. 0.250-0.254---I (a)0.200-0.2032BACB30NX6K( )XBOLT, PROTRUDING HD J -0.200-0.2032BACC30M6COLLAR (a)0.200-0.2035BACB30NX6K3XBOLT, PROTRUDING HD K -0.200-0.2035BACC30M6COLLAR --25BACR15BB6D7CRIVET, UNIVERSAL HD L (a) Install wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted procedure. (b) Touch up bolt head, washer/nut, or collar, as applicable, below door lower frame with BMS 10-11, Type I primer and BMS 10-11 Type II enamel, color BAC 702 white gloss. Refer to SOPM 20-41-02 for an ac- cepted procedure. FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 12 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 47 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 48 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT 2439023 FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 1 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 757-52A0094 Work - See page 1 for details. 48 of 65 ### Page 49 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 612.9 CAM SUPPORT ASSEMBLY 16 LOCATIONS A 1 SUPPORT ASSEMBLY D000B 16 17 10 LOCATIONS BRACKET 12 14 6 LOCATIONS (4 LOCATIONS) RADIUS FILLER 13 TENSION TIE CLIP — PART PROFILE SHOWN IS REFERENCE ONLY 2439066 FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 2 OF 12) Original Issue: December 23, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-52A0094 Work - See page 1 for details. 49 of 65 ### Page 50 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT 80U 1 15 18 STA 580 WEB STA 600 CAM SUPPORT ASSEMBLY 16 LOCATIONS (7 17 (4 LOCATIONS) RADIOS FILLER 13 BRACKET 6 LOCATIONS (12) 14 6 3 18 10 17 17 TENSION TIE CLIP 15 18 € € 8 18 11 9 11 15) 18) SHEAR WEB ASSEMBLY CAM AND BELLCRANK 2444076 FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 3 OF 12) Original Issue: December 23, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 757-52A0094 Work - See page 1 for details. 50 of 65 ### Page 51 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT STA 612.9 CAM SUPPORT ASSEMBLY ALE ME NIE ALE ME SHEAR WEB CAM SUPPORT ASSEMBLY ALE B : BRACKET SHEAR WEB TENSION TIE CLIP A-A TENSION TIE CLIP B-B 2444077 FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 4 OF 12) Original Issue: December 23, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-52A0094 Work - See page 1 for details. 51 of 65 ### Page 52 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT CAM SUPPORT ASSEMBLY STA CAM SUPPORT 600 ASSEMBLY SHEAR WEB 7 7 7 7% TENSION TIE CLIP D-D - BRACKET SHEAR WEB TENSION TIE CLIP C-C 2442471 FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 5 OF 12) Original Issue: December 23, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-52A0094 Work - See page 1 for details. 52 of 65 ### Page 53 (OCR) BOEING SERVICE BULLETIN 757-52A0094 ALERT ALERT CAM SUPPORT ASSEMBLY STA 612.9 CAM SUPPORT ASSEMBLY • CAM SUPPORT CAM SUPPORT ASSEMBLY ASSEMBLY SHEAR WEB STA STA 612.9 E-E 600 FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 6 OF 12) Original Issue: December 23, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 757-52A0094 Work - See page 1 for details. 53 of 65 ### Page 54 The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for each airplane. More DataQtyIdentificationNameTaskStep -1-WEBRemove / Keep1 1-CAM AND BELL- CRANK ASSEMBLY Keep spacers.2-TENSION TIE CLIP -1-SHEAR WEB 2-BRACKET 1-SUPPORT ASSEMBLY Keep cam support assembly at STA 600 for use as an aid during alignment of new cam support assembly. 2-CAM SUPPORT AS- SEMBLY Remove Temporary install using existing holes to maintain original position. 1-CAM SUPPORT AS- SEMBLY Install (Kept)2 -169-23588U10CAM SUPPORT AS- SEMBLY Put / Hold (New)3 1-BRACKETPut / Hold (Kept) (a)1-SUPPORT ASSEMBLY -1-CAM AND BELL- CRANK ASSEMBLY Install (Temporary) Pick up existing holes. -69-23588U10CAM SUPPORT AS- SEMBLY Drill4 --BRACKET Pick up existing holes. (a) --SUPPORT ASSEMBLY -1-CAM AND BELL- CRANK ASSEMBLY Remove / Keep5 1-CAM SUPPORT AS- SEMBLY Remove (Kept) FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 7 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 54 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 55 More DataQtyIdentificationNameTaskStep -169-23588U9CAM SUPPORT AS- SEMBLY Put / Hold (New)6 1-BRACKETPut / Hold (Kept) 1-CAM AND BELL- CRANK ASSEMBLY Install (Temporary) Pick up existing holes. -69-23588U9CAM SUPPORT AS- SEMBLY Drill7 --BRACKET -1-CAM AND BELL- CRANK ASSEMBLY Remove / Keep8 169-23588U9CAM SUPPORT AS- SEMBLY 169-23588U10CAM SUPPORT AS- SEMBLY 2-BRACKET 1-SUPPORT ASSEMBLY -169-23588U9CAM SUPPORT AS- SEMBLY Install (Temporary)9 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP Pick up existing holes in shear web and tension tie clip. -69-23588U9CAM SUPPORT AS- SEMBLY Drill (Kept)10 -69-23588U10CAM SUPPORT AS- SEMBLY --SHEAR WEB --TENSION TIE CLIP -169-23588U9CAM SUPPORT AS- SEMBLY Remove / Keep11 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Keep spacers.2-TENSION TIE CLIP FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 8 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 55 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 56 More DataQtyIdentificationNameTaskStep (b)-69-23588U9CAM SUPPORT AS- SEMBLY Drill (Kept)12 -69-23588U10CAM SUPPORT AS- SEMBLY --SHEAR WEB ----Clean/Deburr (c)8-RADIUS FILLERMake13 Bench work. Install radius fillers at 3 lo- cations on each cam support assembly. 169-23588U9CAM SUPPORT AS- SEMBLY Assemble14 169-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Assembled cam support assemblies and shear web. 169-23588U9CAM SUPPORT AS- SEMBLY Put / Hold15 69-23588U10CAM SUPPORT AS- SEMBLY 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP ---SHEAR WEBDrill16 ----Clean/Deburr17 (d) (e)169-23588U9CAM SUPPORT AS- SEMBLY Install (Kept)18 169-23588U10CAM SUPPORT AS- SEMBLY -2-BRACKET 1-SUPPORT ASSEMBLY Install radius fillers at remaining loca- tions. 1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP Refer to CMM 52- 32-03 for an accept- ed procedure. 1-CAM AND BELL- CRANK ASSEMBLY FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 9 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 56 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 57 More DataQtyIdentificationNameTaskStep Fay and fillet seal with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted proce- dure. 1-WEBInstall (Kept)19 Refer to 757 AMM 12-21-23 for an ac- cepted procedure. -BMS 3-33GREASEApply20 (a) The door hook mechanism can be used as an aid to position the support assembly. Additional put/hold and drilling tasks may be necessary for the support assembly and are as required. (b) Bench work. Temporary assemble through holes common to the tension tie clip. Maintain the main cargo door frame-to-frame mounting surface distance between the cam support assemblies during drilling. (c) Make from 2024-T3 alclad, 2024-T4 alclad, or 7075-T6 alclad aluminum. Approximately 0.75 inch square by 0.125 inch thick. Optional to make in one piece rather than 4. Radius bottom of filler to fit curvature of fitting (0.010 inch maximum gap prior to fastener installation. Apply chemical conversion coating Type 1 or Type 2, Class A or C. Refer to SOPM 20-43-03 as an accepted procedure. Apply two coats of BMS 10-11, Type I primer. Refer to SOPM 20-41-02 for an accepted procedure. (d) Apply one layer of BMS 10-11, Type II enamel, color BAC 702 white gloss below door lower frame, except in cam latch bores, prior to installation of cam and bellcrank assembly. Refer to SOPM 20-41-02 for an accepted procedure.. (e) Apply BMS 3-23, Type II corrosion inhibiting compound above and below door lower frame, except in cam latch bores, prior to installation of cam and bellcrank assembly. Refer to 757 CPM 52-30-01 and SOPM 20-41-05 for an accepted procedure. FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 10 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 57 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 58 The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the number of fasteners necessary for this figure. More DataHole DiaQtyIdentificationNameCode (a)0.325-0.32818BACB30MY10K( )XBOLT, PROTRUDING HD A -0.325-0.32818BACC30M10COLLAR (a)0.325-0.3281BACB30NW10K7XBOLT, 100 DEG HEX DR B -0.325-0.3281BACC30M10COLLAR (a)0.388-0.3911BACB30MY12K10XBOLT, PROTRUDING HD C -0.388-0.3911BACC30M12COLLAR (a)0.2651-0.26618BACB30MY8K( )XBOLT, PROTRUDING HD D -0.2651-0.26618BACC30M8COLLAR (a)0.2651-0.26614BACB30LM4-( )XBOLTE -0.2651-0.26614BACW10AW4ASWASHER, OVERSIZE -0.2651-0.26614BACN10JC4CDNUT,SELF-LOCKING (a)0.2651-0.26614BACB30NW8K( )XBOLT, 100 DEG HEX DR F -0.2651-0.26614BACC30M8COLLAR --4BACR15GF8D14RIVET, 100 DEGG (a) (b)0.2651-0.266110BACB30LM4-( )XBOLTH (b)0.2651-0.266110BACW10AW4ASWASHER, OVERSIZE (b)0.2651-0.266110BACN10JC4CDNUT,SELF-LOCKING (a) (b)0.263-0.2661BACB30MY8K7XBOLT, PROTRUDING HD I (b)0.263-0.2661BACC30M8COLLAR (a)0.200-0.2032BACB30NX6K( )XBOLT, PROTRUDING HD J -0.200-0.2032BACC30M6COLLAR (a)0.200-0.2035BACB30NX6K4XBOLT, PROTRUDING HD K -0.200-0.2035BACC30M6COLLAR FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 11 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 58 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 59 More DataHole DiaQtyIdentificationNameCode --25BACR15BB6D7CRIVET, UNIVERSAL HD L (a)0.325-0.32811BACB30MY10K( )XBOLT, PROTRUDING HD M -0.325-0.32811BACC30AG10COLLAR ASSEMBLY (a)0.325-0.3281BACB30NW10K15XBOLT, 100 DEG HEX DR N -0.325-0.3281BACC30AG10COLLAR ASSEMBLY Pick up existing hole in the pressure door hinge structure. Use the existing fastener. 0.250-0.254---O (a) Install wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted procedure. (b) Touch up bolt head, washer/nut, or collar, as applicable, below door lower frame with BMS 10-11, Type I primer and BMS 10-11 Type II enamel, color BAC 702 white gloss. Refer to SOPM 20-41-02 for an ac- cepted procedure. FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT (SHEET 12 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 59 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT ### Page 60 Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source for tasks required for compliance. 1. The table below gives the description for the parts and conditions called out in the logic diagrams. DescriptionTitle MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENTPART 1 NO CRACK FOUNDCONDITION 1 ANY CRACK FOUNDCONDITION 2 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY - INSPECTION (SHEET 1 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: December 23, 2015 757-52A0094 60 of 65 BOEING SERVICE BULLETIN 757-52A0094 ALERTALERT The text continues at https://openairdocs.org/service-documents/boeing/757-52a0094/file/42f701892e63.md?from=61 --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.