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Commercial Airplanes 707 Service Bulletin ALERT Number: A3536 Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 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 © 2012 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Unpublished Work.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 06, 2012 A3536Revision 1: September 16, 2015 1 of 82
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 2 of 82 BOEING SERVICE BULLETIN A3536
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
S u m m a r y7
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 2 5 G. Manpower .............................................. 2 6 H. Weight and Balance Changes .................................... 2 7 I. Electrical Load Data ......................................... 2 7 J . R e f e r e n c e s .............................................. 2 7
1. Existing Data: ......................................... 2 7
2. Data Supplied with this Service Bulletin: ........................... 2 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 7 K. Publications Affected ........................................ 2 8 L. Interchangeability and Intermixability of Parts ........................... 2 8 M. Software Accomplishment Summary ................................ 2 8
2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 2 9 C. Parts Necessary for Each Airplane ................................. 2 9 1 . K i t s / P a r t s ............................................ 2 9
2. Parts and Materials Supplied by the Operator ........................ 2 9
3. Parts Modified and Reidentified ................................ 3 0
4. Parts Removed and Not Replaced .............................. 3 0 D. Parts Necessary to Change Spares ................................. 3 0 E. Special Tooling - Price and Availability ............................... 3 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 5 FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION ......... 3 9 FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT ..... 4 2 FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT ............ 4 4 FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION ........ 4 6 FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT ........... 4 8 FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT ................... 5 0 FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT .................... 5 3 FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION ........... 5 5 FIGURE 9: MAIN CARGO DOOR - CAM LATCHES, LATCH PINS AND LATCH PIN CROSS BOLTS INSPECTION .......................................... 5 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING ............. 6 0 FIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT . . 63 APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST ......................... 6 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 707 Service Bulletin ALERT Revision Transmittal SheetNumber: A3536Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2012-NM-132-AD, is related to this service bulletin.
Effects of this Revision on airplanes on which Original Issue was previously done:
None.
REASON FOR REVISION This revision is sent to clarify the requirements of the compliance tables.
These sections were changed:
1. Summary - BACKGROUND: Text revised to include more detailed information. Summary Evaluation Table revised to reflect this revision.
2. Summary - ACTION: Text revised to include more detailed information.
3. Summary - Compliance: Notice of Proposed Rule Making (NPRM) statement added.
4. Summary - Graphic: Illustration revised to align with the changes made in this revision.
5. Paragraph 1.C. Reason: Text revised to include more detailed information.
6. Paragraph 1.D. Description: Text revised to include more detailed information.
7. Paragraph 1.E. Compliance: NPRM statement added. Compliance Tables 1 and 2 revised to clarify inspections, conditions and actions.
8. Paragraph 1.G. Manpower: Footnote in table revised to show NDI inspection.
9. Paragraph 1.H. Weight and Balance: Table added to show the 707-300/-300B/-300C airplanes.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 5 of 82
10. Paragraph 1.K. Publications Affected: Added a table to show the different publications affected, and DTI statement added.
11. Paragraph 1.M. Software Accomplishment. Added.
12. Paragraph 2.C.2. Parts and Materials Supplied by the Operator: Added footnote (g).
13. Paragraph 3.A. General Information: Added new information.
14. Paragraph 3.B. Work Instructions: Revised to show new conditions and text.
15. Figures 1 thru 9: Illustrations and step tables revised to align with the changes made in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY February 06, 2012Original Issue:
September 16, 2015Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 6 of 82 BOEING SERVICE BULLETIN A3536
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Commercial Airplanes 707 Service Bulletin ALERT SummaryNumber: A3536Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND Accomplishment of the inspections in this service bulletin will make sure the Main Cargo Door (MCD) cam latches are inspected for damage and the latch pins are inspected for damage and migration. The inspections are necessary in order to find and replace damaged cam latches, latch pins and latch pin cross bolts. If not replaced, damaged cam latches, latch pins and latch pin cross bolts could lead to a failure of the cam latches and may result in a possible rapid decompression and potential separation of the main cargo door from the airplane.
Boeing has received one report from one 757 operator that the MCD forward most cam latch on the forward center cam latch pair (cam latch number 3) broke during flight. The 757 airplane with the reported broken cam latch had accumulated 20,000 flight hours and 9,500 flight cycles when the cam latch broke. The crew heard a loud noise coming from the MCD shortly after reaching cruise. Upon landing, an inspection was performed and a cam latch was found broken. The broken cam latch mating latch pin was also found to have significant wear as evidenced by the loss of the plating on the surface that is normally in contact with the cam latch. The latch pin was also deformed approximately 0.05 inch in the area of the wear surface. The latch pin cross bolt was unserviceable.
The 707 MCD is of similar design to the 757 MCD. Boeing has not received any reports of a broken cam latch on a 707 MCD.
The cause of the broken cam latch has been determined to be from a poorly rigged MCD. Although properly rigged per the original Aircraft Maintenance Manual (AMM) procedures, significant variation was allowed in the rigging dimensions. This variation can cause some of the latch pin/cam latch locations to have a significant preload placed on them during engagement and rotation of the cam latches during latching and unlatching operations. This preload is believed to have imparted a torque on the latch pin from the cam latch rotation during latching and unlatching operations. The torque transmitted to the latch pin is then believed to have caused the latch pin cross bolt to fail in shear.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 7 of 82
If the latch pin cross bolt fails, the latch pin could migrate either towards the cam latch or away from the cam latch. Latch pin migration towards the cam latch can cause significant interference with the mating cam latch leading to cam latch damage. In the 757 case, the latch pin migrated into the cam latch and caused damage to the cam latch. The crack initiated at the damage site caused by the latch pin and then led to the cam latch breaking. Latch pin migration away from the cam latch could cause disengagement from the cam latch, resulting in no load transfer between the cam latch and the mating latch pin and may not be noticed before critical conditions are exceeded in adjacent cam latches or latch pins.
Accomplishment of the work given in this service bulletin will make sure the cam latches, latch pins and latch pin cross bolts are inspected and repaired or replaced as required. The MCD rig will be verified to the Service Bulletin requirements.
Boeing Service Related Problem (SRP) 707-52-0088 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 707 FTD 52-09001 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 Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION Get access to the MCD. Do a general visual inspection of the cam latches, latch pins and latch pin cross bolts.
Torque the cross bolts in the latch pins. Measure the extension of the latch pins. Replace all alloy steel cross bolts through the latch pins with Corrosion Resistant Steel (CRES) cross bolts. Check for lip deformation on all cam latches. Do a High Frequency Eddy Current (HFEC) or magnetic particle inspection of cam latch 1 and cam latch 2 for cracks. Replace any cracked or broken parts. Check the rig of the MCD and do the latch mechanism adjustment test to the requirements of the Service Bulletin. Do repetitive general visual and detailed inspections of the cam latches and latch pins after the rig is verified or adjusted. Do repetitive HFEC or magnetic particle inspections of cam latch 1 and cam latch 2 for cracks after the rig is verified or adjusted.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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EFFECTIVITY 707-300, 707-300B and 707-300C airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
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.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2012-NM-132-AD, is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and modifications given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN A3536
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MAIN CARGO DOORWAY
• D LOWER SILL RAD O D
LATCH PIN
- DO A GENERAL VISUAL INSPECTION OF THE CAM LATCHES, LATCH PINS, AND LATCH PIN CROSS BOLTS.
TORQUE THE LATCH PIN CROSS BOLTS IN THE LATCH PINS.
MEASURE THE EXTENSION OF THE LATCH PINS
REPLACE ALL THE ALLOY STEEL CROSS BOLTS THROUGH THE
LATCH PINS WITH CRES LATCH PIN CROSS BOLTS CHECK FOR LIP DEFORMATION ON ALL CAM LATCHES.
DO A HFEC OR MAGNETIC PARTICLE INSPECTION OF CAM LATCH 1 AND CAM LATCH 2 FOR CRACKS.
CHECK THE RIG OF THE MCD REPLACE DAMAGED LATCH PINS AND CAM LATCHES.
RIG THE MCD IF NECESSARY DO REPETITIVE POST-RIG CHECK INSPECTIONS.
CAM LATCH 2403702 Original Issue: February 06, 2012 Revision 1: September 16, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING A3536 Work - See page 1 for details. 10 of 82
Commercial Airplanes 707 Service Bulletin ALERT Number: A3536 Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, LineNumber, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 707-300, 707-300B and 707-300C airplanes with a Main Cargo Door-1 Airplane Models:
707-300, 707-300B, 707-300C GroupVariable Number 102017 105601 - 05605 106461 107001 - 07017 107041 - 07059 107071 - 07081 107101 - 07109 107181 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 11 of 82
GroupVariable Number 107191 107201 - 07215 107251 - 07271 107401 - 07407 107451 - 07458 107501 - 07504 107601 - 07626 107661 - 07662 107681 - 07684 107701 - 07702 107801 - 07821 107901 - 07907 108001 - 08008 108021 108051 - 08056 108071 - 08077 108101 - 08104 108121 - 08129 108141 - 08144 108151 - 08153 108171 - 08173 108191 - 08192 108201 - 08210 108221 - 08224 108241 - 08244 108251 108261 108271 108301 - 08320 108324 - 08330 108333 108401 - 08410 108451 - 08452 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 12 of 82 BOEING SERVICE BULLETIN A3536