# Boeing Service Bulletin A3536: Revision 1 - Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2013-0215; AD 2016-19-16 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication. - Document: [Boeing Service Bulletin A3536](https://openairdocs.org/service-documents/boeing/a3536.md) - Title as filed: FAA-2013-0215_SB-707-A3536_R1 - Pages: 82 - PDF: https://openairdocs.org/files/sha256/30/66/306691e7ba93fb15d8c27ebfb99f6592191e5beae1b9730585d507f346bf36b9 - Page: https://openairdocs.org/service-documents/boeing/a3536/file/306691e7ba93 ## 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 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 Unpublished Work.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1: September 16, 2015 1 of 82 4.0 ### Page 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 ALERTALERT BLANK PAGE ### Page 3 Table of Contents Revision Transmittal Sheet ............................................ 5 S u m m a r y ...................................................... 7 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. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 3 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 4 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. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 4 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 5 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 ### Page 6 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 ALERTALERT ### Page 7 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 ### Page 8 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 Air- plane 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. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 8 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 9 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. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 9 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 10 (OCR) BOEING SERVICE BULLETIN A3536 ALERT ALERT 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 ### Page 11 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 ### Page 12 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 ALERTALERT ### Page 13 GroupVariable Number 108471 - 08475 108501 - 08502 108551 - 08553 108581 - 08582 109001 - 09006 109101 - 09107 109161 - 09167 109201 - 09204 109221 - 09223 109227 109231 - 09232 109251 109271 109281 109286 - 09290 109411 109421 109438 109441 2. Spares Affected None. B. Concurrent Requirements The service bulletin listed below must be done in accordance with FAA Airworthiness Directive AD 91-22-04. If the service bulletin below has not previously been accomplished as required by AD 91-22-04, then it must be accomplished before further flight. DescriptionService BulletinCompany Replaces the latch cam and the pressure relief door hinge fitting on the main cargo door. 707-3477 Revision 2. (a)The Boeing Company (a) The work given in Boeing Service Bulletin 707-3477 Revision 2 is necessary to comply with FAA Airwor- thiness Directive AD 91-22-04. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 13 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 14 C. Reason 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. 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. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 14 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 15 D. Description 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. Revision 1 - Effects of this Revision on airplanes on which Original Issue was previously done: None. The work in this service bulletin is done in the maintenance zone(s) given below. Affected Maintenance Zones ZoneModel 2-49707-300, 707-300B, 707-300C 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. Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2012-NM-132-AD, is related to this service bulletin. If all Table 1 requirements, including rigging of the main cargo door, have been accomplished in accordance with the original issue of this service bulletin, continue repetitive inspections in accordance with Table 2. If Table 1 requirements have not been accomplished in accordance with the original issue of this service bulletin, then all Table 1 requirements, including rigging of the main cargo door, must be accomplished before starting Table 2 requirements. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 15 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 16 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Within 150 days after the original issue date of this service bul- letin. Within 330 flight cycles after the original issue date of this ser- vice bulletin. Do the following for all MCD cam latches and latch pins: Do a general visual in- spection for any broken cam latches, latch pins and latch pin cross bolts, and for any missing cam latches, latch pins and latch pin cross bolts in accordance with Step 1.b. All airplanes AND Torque the cross bolts in the latch pins in accor- dance with Step 1.c. AND Measure the extension of the latch pins in accor- dance with Step 1.d. AND Do a general visual in- spection of all cam latch- es for lip deformation in accordance with Step 1.e. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 16 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 17 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Before further flight Replace broken and missing cam latches, latch pins and latch pin cross bolts in accordance with Step 2.a. Condition 1: One or more of the following is found: 1. Broken or missing cam latch(es). 2. Broken or missing latch pin(s). 3. Broken or missing latch pin cross bolt(s). AND Do a detailed inspection of mating part(s) and im- mediately adjacent cam latch(es) and latch pin(s) for any cracks, or any gouges in critical areas in accordance with Step 2.b. AND Unless replaced with new or reworked parts,do a HFEC or magnetic parti- cle inspection of cam latch 1 and cam latch 2 for any cracks in accor- dance with Step 2.c. (b) AND Check the rig of the MCD and do the latch mecha- nism adjustment test in accordance with Step 2.d. AND Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 2.d. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 17 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 18 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Within 150 days after the latch pin extension was measured. Within 330 flight cycles after the latch pin exten- sion was mea- sured. Replace the discrepant latch pin in accordance with Step 3.a. AND Do a detailed inspection of the mating cam latch for any cracks, or gouges in critical areas in accor- dance with Step 3.b. Condition 2: The latch pin extension is less than 0.89 inches or greater than 0.91 inches. 330 flight cycles or 150 days, whichever occurs first. (a) --Do the following for all MCD cam latches and latch pins: Do a general visual in- spection for any broken cam latches, latch pins and latch pin cross bolts, and for any missing cam latches, latch pins and latch pin cross bolts in accordance with Step 3.c. AND -Within 24 months after the original issue date of this ser- vice bulletin. Within 3,000 flight cycles af- ter the original issue date of this service bul- letin. Do a detailed inspection of all latch pin(s) and mating cam latch(es) for any cracks, or gouges in critical areas in accor- dance with Step 3.d. -Within 24 months after the original issue date of this ser- vice bulletin. Within 3,000 flight cycles af- ter the original issue date of this service bul- letin. Unless replaced with new or reworked parts, do a HFEC or magnetic parti- cle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 3.e. (b) AND Check the rig of the MCD and do the latch mecha- nism adjustment test in accordance with Step 3.f. AND Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 18 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 19 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 3.f. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 19 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 20 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition 330 flight cycles or 150 days, whichever occurs first. (a) Within 150 days after the initial inspection. Within 330 flight cycles after the initial inspection. Do a detailed inspection of the discrepant cam latch and mating latch pin for any cracks, or gouges in critical areas in accor- dance with Step 4.a. Condition 3: If a cam latch is found with lip deforma- tion. AND 330 flight cycles or 150 days, whichever occurs first. (a) --Do the following for all MCD cam latches and latch pins: Do a general visual in- spection for any broken cam latches, latch pins and latch pin cross bolts, and for any missing cam latches, latch pins and latch pin cross bolts in accordance with Step 4.b. AND -Within 24 months after the original issue date of the ser- vice bulletin. Within 3,000 flight cycles af- ter the original issue date of the service bulletin. Do a detailed inspection of all latch pin(s) and mating cam latch(es) for any cracks, or gouges in critical areas in accor- dance with Step 4.c. AND -Within 24 months after the original issue date of the ser- vice bulletin. Within 3,000 flight cycles af- ter the original issue date of the service bulletin. Unless replaced with new or reworked parts, do a HFEC or magnetic parti- cle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 4.d. (b) AND Check the rig of the MCD and do the latch mecha- nism adjustment test in accordance with Step 4.e. AND Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 20 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 21 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 4.e. 330 flight cycles or 150 days, whichever occurs first. (a) --Do a general visual in- spection for any broken or missing cam latches, latch pins and latch pin cross bolts in accordance with Step 5.a. Condition 4: No discrepan- cies found (c) 3,000 flight cycles or 24 months, whichever occurs first. (a) Within 24 months after the initial inspection. Within 3,000 flight cycles af- ter the initial in- spection. Do a detailed inspection of the cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with Step 5.b. AND Unless replaced with new or reworked parts, do a HFEC or magnetic parti- cle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 5.c. (b) -Within 48 months after the original issue date of this ser- vice bulletin. Within 6,000 flight cycles af- ter the original issue date of this service bul- letin. Check the rig of the MCD and do the latch mecha- nism adjustment test in accordance with Step 5.d. AND Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 5.d. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 21 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 22 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition -Before further flight.Replace cracked or gouged cam latch(es) and latch pin(s) in accor- dance with Step 6.a. Condition 5: If the detailed, HFEC or magnetic particle inspections specified in the Actions of Conditions 1 thru 4 reveal any of the follow- ing: AND Do a detailed inspection of mating part(s) and im- mediately adjacent cam latch(es) and latch pin(s) for any cracks, or any gouges in critical areas in accordance with Step 6.b. Do all applicable correc- tive actions as described in Condition 5. 1. Cracked or gouged cam latch(es) in critical areas. 2. Cracked or gouged latch pin(s) in critical areas. AND Unless replaced with new or reworked parts,do a HFEC or magnetic parti- cle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 6.c. Do all applica- ble corrective actions as described in Condition 5. (b) AND Check the rig of the MCD and do the latch mecha- nism adjustment test in accordance with Step 6.d. AND Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 6.d. (a) All Table 1 repeat inspections are terminated when the rig of the MCD has been checked in accordance with Paragraph 3.B., Work Instructions. Refer to Table 2 for post-rig check inspection requirements. (b) A reworked cam latch is defined as a cam latch that has been reworked within limits of CMM 52-36-61 and/or a Boeing ODA approved repair via FAA Form 8100-9 and has been HFEC or magnetic particle inspected, and has no crack(s) or gouge(s) in critical area(s). Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 22 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 23 Table 1: Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) ActionCondition (c) Discrepancy is defined as: Any broken, cracked, missing or gouged cam latches or latch pins, broken or missing latch pin cross bolts, latch pin extension less than 0.89 inches or greater than 0.91 inches, or cam latch lip deformation. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 23 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 24 Table 2: Repetitive Inspection Requirements for Airplanes that have accomplished All Table 1 Require- ments, Including Rigging of the Main Cargo Door in accordance with the Original Issue or Revision 1 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance TimeActionCondition 375 flight cycles.Within 375 flight cycles after the rig of the MCD was checked. Do a general visual in- spection for any broken or missing cam latch(es), latch pin(s) and latch pin cross bolt(s) in accor- dance with Step 7.a.(1) All Airplanes that have ac- complished all Table 1 re- quirements,including rig- ging of the main cargo door in accordance with the original issue or revision 1 of this service bulletin and no rigging adjustment of any latch pin or any latch pin fitting was required. 3,000 flight cycles.If latch pin flight cycles are known: Before 20,000 total latch pin flight cycles. Do a detailed inspection of the latch pins for any cracks, or any gouges in critical areas in accor- dance with Step 7.a.(2) 3,000 flight cycles.If latch pin flight cycles are un-known:ANDDuring previous pre-rig check inspection, no dis- crepancy was found. (b) Within 3,000 flight cycles after the rig of the MCD was checked. 3,000 flight cycles.If cam latch flight cycles are known and cam latch is not a re- worked part: (a) Do a detailed inspection of the cam latches for any cracks, or any gouges in critical areas in accor- dance with Step 7.a.(2) Before 20,000 total cam latch flight cycles. 3,000 flight cycles.If cam latch flight cycles are un- known or if cam latch is a re- worked part: (a) Within 3,000 flight cycles after the rig of the MCD was checked. 6,000 flight cycles.If cam latch flight cycles are known and cam latch is not a re- worked part: (a) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 7.a.(3) Before 20,000 total cam latch flight cycles. 6,000 flight cycles.If cam latch flight cycles are un- known or if cam latch is a re- worked part: (a) Within 6,000 flight cycles after the rig of the MCD was checked. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 24 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 25 Table 2: Repetitive Inspection Requirements for Airplanes that have accomplished All Table 1 Require- ments, Including Rigging of the Main Cargo Door in accordance with the Original Issue or Revision 1 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance TimeActionCondition 375 flight cycles.Within 375 flight cycles after the rig of the MCD was checked. Do a general visual in- spection for any broken or missing cam latch(es), latch pin(s) and latch pin cross bolt(s) in accor- dance with Step 8.a.(1) All Airplanes that have ac- complished all Table 1 re- quirements, including rig- ging of the main cargo door in accordance with the original issue or revision 1 of this service bulletin and rigging adjustment of any latch pin or any latch pin fitting was required. 3,000 flight cycles.Within 3,000 flight cycles after the rig of the MCD was checked. Do a detailed inspection of the cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with Step 8.a.(2) OR During previous pre-rig check inspection, any dis- crepancy was found. (b) 6,000 flight cycles.Within 6,000 flight cycles after the rig of the MCD was checked. Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 8.a.(3) -Before further flight.Contact The Boeing Company for repair in- structions and do the re- pair. Any discrepancy found. (a) A reworked cam latch is defined as a cam latch that has been reworked within limits of CMM 52-36-61 and/or a Boeing ODA approved repair via FAA Form 8100-9 and has been HFEC or magnetic particle inspected, and has no crack(s) or gouge(s) in critical area(s). (b) Discrepancy is defined as: Any broken, cracked, missing or gouged cam latches or latch pins, broken or missing latch pin cross bolts, latch pin extension less than 0.89 inches or greater than 0.91 inches, or cam latch lip deformation. F. Approval This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other approved Boeing changes. If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this service bulletin. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 25 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 26 G. Manpower The table below shows an estimate of the task hours necessary to do the inspections and modifications for each airplane. 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. Elapsed HoursTask HoursNumber of PersonsTask 0.250.251Open Access 1.601.601FIGURE 1 0.500.501FIGURE 2 0.500.501FIGURE 3 1.00 (h)1.00 (h)1FIGURE 4 1.001.001FIGURE 5 0.50 (a) (f) (i)0.50 (a) (f) (i)1 (i)FIGURE 6 0.10 (b) (g)0.10 (b) (g)1FIGURE 7 0.60 (c)0.60 (c)1FIGURE 8 0.10 (d)0.10 (d)1FIGURE 9 20.0048.002-3FIGURE 10 - FIG- URE 11 0.250.251Close Access (e)(e)TOTAL FOR EACH AIRPLANE (a) Estimate is per cam latch requiring replacement. (b) Estimate is per latch pin requiring replacement. (c) Estimate is per cam latch requiring inspection. (d) Estimate is per cam latch. (e) Total time required may vary depending upon conditions found during inspec- tions. (f) Does not include time to match drill cam shaft. (g) Does not include time to match drill latch pin. (h) Does not include NDI inspection time. (i) Cam latch 4 will require 2 hours and a second person to remove. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 26 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 27 H. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds)Airplane NegligibleNegligible707-300 NegligibleNegligible707-300B NegligibleNegligible707-300C I. Electrical Load Data Not applicable. J. References 1. Existing Data: a. Boeing Service Bulletin 707-3477 b. Boeing Service Letter 707-SL-51-029 c. Boeing Service Related Problem (SRP) 707-52-0088 d. Component Maintenance Manual (CMM) 52-36-61 e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 91-22-04 f. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM) 2012-NM-132-AD g. Aircraft Maintenance Manual (AMM) 707 AMM 52-11-0 h. Standard Overhaul Practices Manual (SOPM) 20-20-01 i. 707, 720 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00 j. 707 Fleet Team Digest (FTD) 52-09001 k. 707-300/400 Structural Repair Manual (SRM) 51-00-06 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin: TitleDrawing Number DOOR INSTALLATION - MAIN CARGO65-25326 LATCH MECHANISM INSTALLATION - MAIN CARGO DOOR65-25339 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 27 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 28 TitleDrawing Number SILL INSTL - LOWER, MAIN CARGO DOOR65-25343 LATCH PIN FITTING - ASSY65-25771 CAM - LATCH MECHANISM CARGO DOOR69-23438 BODY INSTALLATION - SECTION 4350-2543 The table above lists applicable drawings used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected 1. Publications Chapter-SectionPublication 52-11707 Aircraft Maintenance Manual 52-03707 Illustrated Parts Catalog 52-36-61Component Maintenance 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. Repairs accomplished on cam latch(es) in accordance with CMM 52-36-61 are structurally acceptable as Category A repairs as defined as: "A permanent repair for which the inspections given in the Maintenance Planning Data (MPD) document, are sufficient and no other actions are necessary", therefore no supplemental inspections to the mandated damage tolerance inspections contained in Paragraph 1.E., Compliance, Table 2, of this service bulletin, are required. 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: February 06, 2012 A3536Revision 1: September 16, 2015 28 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 29 2. MATERIAL INFORMATION A. Material - Price and Availability The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each Airplane . As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin does not show the Boeing price and supply data. B. Industry Support Information Boeing warranty remedies are not available for the inspections and modifications given in this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts None. 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. NotesNameQTYPart Number / Specification (a) (b)BOLT, HEX HEAD, 160 KSI MIN TENSILE, LONG THREAD, A286,NON LOCKING 8BACB30LM3-24 OR BACB30LM3-22 Parts are only needed if ex- isting part cannot be re- worked. (c) (g) Cam Latch 1-69-23438-2 Cam Latch 2-143N8060-1 Cam Latch 3-143N8027-2 Cam Latch 4-69-23439-3 Cam Latch 5-69-23439-4 Cam Latch 6-143N8027-1 Cam Latch 7-143N8060-2 Cam Latch 8-69-23438-1 Latch Pin-6-83137-2 (d)Corrosion Inhibiting Compound5 oz.BMS 3-27 (d)Pressure and Environmental Sealant5 oz.BMS 5-95, TYPE I, CLASS B 1/2 (e)Flexbar ReproRubber Quicksetting Putty or equivalent 8 oz.- (f)Rod, 3/16 diameter, 2 inches long1- Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 29 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 30 NotesNameQTYPart Number / Specification (a) Refer to 707 Structural Repair Manual Chapter 51 for alternate fasteners. (b) BACB30LM3-24 is used if optional 143N8157-2 Clip Assembly is installed. (c) Drill attachment holes to the new latch cam to match with the existing bell crank assembly to ensure proper installation and clocking. (d) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (e) Available from Flexbar Machine Corp. (2R260), 250 Gibbs Road, Islandia, NY 11749,USA. (f) Used for aligning the rigging pin slot with the cross bolt hole in accordance with APPENDIX A. (g) Part numbers and quantities necessary are dependent on inspection findings. 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 Boeing can supply the tool(s) shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The tool(s) are subject to the terms and conditions of the Boeing standard purchase order acknowledgement. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin number and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 30 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 31 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 Purchase Data: Unit Price as of the Revision 1 date of this Ser- vice Bulletin (US Dollars) NameTool Kit Number 8,821.00Pin Set - Rigging, Main Deck, Main Cargo Door B52029-1 Rental Data: Daily Price as of the Revision 1 date of this ser- vice bulletin (US Dollars) NameTool Kit Number 180.00Pin Set - Rigging, Main Deck, Main Cargo Door B52029-1 F. Special Tooling Necessary to do this Service Bulletin To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available. NameTool Kit Number Pin Set - Rigging, Main Deck, Main Cargo Door B52029-1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 31 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 32 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 32 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT BLANK PAGE ### Page 33 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 707 Structural Repair Manual, Chapter 51. 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. Clearance between fasteners and surrounding structures or mechanisms may be minimal by design at some locations. Use caution when adjusting grip length of fasteners and make sure no interference conditions exist after installation. Interference between moving parts may be difficult to detect. Complete full cycle of mechanisms to ensure no interference conditions exist. 7. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 33 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 34 8. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 9. 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. 10. Boeing Service Letter 707-SL-51-029 Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 11. Refer to APPENDIX A for the Latch Mechanism Adjustment Test. 12. 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. 13. 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. 14. 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. 15. 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. 16. 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. 17. Damage found on cam latch(es) within the reworkable limits of CMM 52-36-61 can be reworked in accordance with CMM 52-36-61. 18. A reworked cam latch is defined as a cam latch that has been reworked within the limits of CMM 52-36-61 and/or a Boeing ODA approved repair via FAA Form 8100-9 and has been HFEC or magnetic particle inspected, and has no crack(s) or gouge(s) in critical area(s). Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 34 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 35 19. Discrepancy is defined as: Any broken, cracked, missing or gouged cam latches or latch pins, broken or missing latch pin cross bolts, latch pin extension less than 0.89 inches or greater than 0.91 inches, or cam latch lip deformation. 20. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. B. WORK INSTRUCTIONS 1. Initial (Pre-Rig Check) Inspections. a. Get access to the Main Cargo Door (MCD). b. Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts and for any missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. c. Torque the cross bolts in the latch pins in accordance with FIGURE 2. d. Measure the extension of the latch pins in accordance with FIGURE 3 e. Do a general visual inspection of all cam latches for lip deformation in accordance with FIGURE 1. 2. Condition 1: One or more of the following is found: – Broken or missing cam latch(es) – Broken or missing latch pin(s) – Broken or missing latch pin cross bolt(s) a. Replace broken and missing cam latch(es) in accordance with FIGURE 6, replace broken and missing latch pin(s) in accordance with FIGURE 7 and replace broken and missing latch pin cross bolt(s) in accordance with FIGURE 5. b. Do a detailed inspection of mating part(s) and immediately adjacent cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with FIGURE 8. Do all applicable corrective actions as described in Condition 5. c. Unless replaced with new or reworked parts, do a High Frequency Eddy Current (HFEC) or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. d. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 3. Condition 2: The latch pin extension is less than 0.89 inches or greater than 0.91 inches: a. Replace the discrepant latch pin in accordance with FIGURE 7. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 35 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 36 b. Do a detailed inspection of the mating cam latch for any cracks, or gouges in critical areas in accordance with FIGURE 8. Do all applicable corrective actions as described in Condition 5. c. Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts and for any missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. Do all applicable corrective actions as described in Condition 1. d. Do a detailed inspection of all the latch pins and mating cam latches for any cracks, or any gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. e. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. f. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. NOTE: Rigging for the latch pin will require it to be installed properly with an extension of 0.90 +/- 0.01 inches. A latch pin with an original extension between 0.84 to 0.94 inches, with no cracks or gouges in critical areas and no other discrepancies may be re-used by clocking the latch pin 90 degrees +/- 10 degrees from original position and match drilling a new cross bolt hole that provides the correct latch pin extension. Fill old cross bolt hole in pin with BMS 5-95 sealant and install pin with BMS 3-27 corrosion inhibiting compound. 4. Condition 3: If a cam latch is found with lip deformation. a. Do a detailed inspection of the discrepant cam latch and mating latch pin for any cracks, or gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. b. Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts and for any missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. Do all applicable corrective actions as described in Condition 1. c. Do a detailed inspection of all cam latches and mating latch pins for any cracks, or any gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. d. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. e. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 5. Condition 4: Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 36 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 37 No discrepancies found: a. Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. Do all applicable corrective actions as described in Condition 1. b. Do a detailed inspection of the cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. c. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. d. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 6. Condition 5: If the detailed, HFEC or magnetic particle inspections in Conditions 1 thru 4 reveal any of the following: – Cracked or gouged cam latch(es) in critical areas. – Cracked or gouged latch pin(s) in critical areas. a. Replace cracked or gouged cam latch(es) in accordance with FIGURE 6, replace cracked or gouged latch pin(s) in accordance with FIGURE 7. b. Do a detailed inspection of mating part(s) and immediately adjacent cam latches and latch pins for any cracks or any gouges in critical areas in accordance with FIGURE 8. Do all applicable corrective actions as described in Condition 5. c. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. d. Check the rig of the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 7. Post Rig Check Repetitive Inspections. a. All Airplanes that have accomplished all Table 1 requirements identified in Paragraph 1.E., Compliance, including rigging of the MCD in accordance with the original issue or Revision 1 of this service bulletin and no rigging adjustment of any latch pin or any latch pin fitting was required, and during previous pre-rig check inspections there were no discrepancies found: (1) Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin Cross Bolt in accordance with FIGURE 9. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 37 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 38 (2) Do a detailed inspection of the cam latches and latch pins for any cracks or any gouges in critical areas in accordance with FIGURE 1. (3) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. (4) If any discrepancy is found, contact The Boeing Company for repair instructions and do the repair. 8. Post Rig Check Repetitive Inspections. a. All Airplanes that have accomplished all Table 1 requirements identified in Paragraph 1.E., Compliance, including rigging of the MCD in accordance with the original issue or Revision 1 of this service bulletin and rigging adjustment of any latch pin or any latch pin fitting was required, or during previous pre-rig check inspections there were any discrepancies found. (1) Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. (2) Do a detailed inspection of the cam latches and latch pins for any cracks or any gouges in critical areas in accordance with FIGURE 1. (3) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. (4) If any discrepancy is found, contact The Boeing Company for repair instructions and do the repair. 9. Put the airplane back to a serviceable condition. Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1: September 16, 2015 38 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 39 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT 2089401 FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION (SHEET 1 OF 3) 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. 39 of 82 ### Page 40 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT LATCH PIN (8 LOCATIONS) CRITICAL AREA ENTIRE CIRCUMFERENCE O.: CRITICAL AREA WEAR PLATE CAM LATCH • LIP DEFORMATION LOCATED OUTSIDE NORMAL WEAR AREAS CRITICAL AREA 2403703 FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION (SHEET 2 OF 3) Original Issue: February 06, 2012 Revision 1 September 16, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3536 Work - See page 1 for details. 40 of 82 ### Page 41 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 this figure. More DataQtyIdentificationNameTaskStep (a) (b)169-23438-2Cam Latch 1Inspect1 (a) (b)1143N8060-1Cam Latch 2Inspect2 (a) (b)1143N8027-2Cam Latch 3Inspect3 (a) (b)169-23439-3Cam Latch 4Inspect4 (a) (b)169-23439-4Cam Latch 5Inspect5 (a) (b)1143N8027-1Cam Latch 6Inspect6 (a) (b)1143N8060-2Cam Latch 7Inspect7 (a) (b)169-23438-1Cam Latch 8Inspect8 (a)86-83137-2Latch PinInspect9 (a) Do Detailed inspection for cracks or gouges in critical areas. (b) Do a general visual inspection for lip deformation. FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 41 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 42 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT MAIN CARGO DOORWAY LOWER SILL LATCH PIN FITTING ASSEMBLY (8 LOCATIONS) LATCH PIN FITTING ASSEMBLY 1 LATCH PIN (SHOWN WITH OPTIONAL CLIP CROSS BOLT ASSEMBLY INSTALLED) 2403704 FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT (SHEET 1 OF 2) Original Issue: February 06, 2012 Revision 1 September 16, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3536 Work - See page 1 for details. 42 of 82 ### 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 this figure. More DataQtyIdentificationNameTaskStep (a)8-Cross BoltTorque1 (a) Make sure the latch pin cross bolt is capable of reaching a 15 pound-inch, +/- 1 pound-inch, torque from the head side of the bolt and also the nut side if no nutplate is used. The 15 pound-inch, +/- 1 pound-inch, torque value is approximately one-half of the installation torque and is used to give an indication of a broken cross bolt. FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 43 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 44 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT MAIN CARGO DOORWAY LOWER SILL > D A ASSEMBL ATCH PIN FITTIN (8 LOCATIONS) 0.89 O 0.89 LATCH PIN FITTING ASSEMBLY (SHOWN WITH OPTIONAL CLIP ASSEMBLY INSTALLED) A WEAR PLATE 2089731 FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT (SHEET 1 OF 2) Original Issue: February 06, 2012 Revision 1 September 16, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3536 Work - See page 1 for details. 44 of 82 ### Page 45 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 this figure. More DataQtyIdentificationNameTaskStep Make sure the latch pin extends out 0.90 inch +/- 0.01 inch from the wear plate. 86-83137-2Latch PinMeasure1 FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 45 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 46 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT + A A 9€ CRITICAL AREA ENTIRE CAM LATCH CIRCUMFERENCE CRITICAL AREA ENTIRE CIRCUMFERENCE 2403705 FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION (SHEET 1 OF 2) Original Issue: February 06, 2012 Revision 1 September 16, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3536 Work - See page 1 for details. 46 of 82 ### Page 47 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 this figure. More DataQtyIdentificationNameTaskStep -169-23438-2Cam Latch 1Remove / Keep1 -1143N8060-1Cam Latch 2Remove / Keep2 Do a HFEC inspec- tion of cam latch 1 for cracks in accor- dance with 707, 720 NDT Manual Part 6, 51-00-00, Figure 13 or Figure 24 (a) (b) (c) 169-23438-2Cam Latch 1Inspect3 Do a HFEC inspec- tion of cam latch 2 for cracks in accor- dance with 707, 720 NDT Manual Part 6, 51-00-00, Figure 13 or Figure 24 (a) (b) (c) 1143N8060-1Cam Latch 2Inspect -169-23438-2Cam Latch 1Install (Kept)4 -1143N8060-1Cam Latch 2Install (Kept)5 (a) Use a 0.080 inch diameter or smaller HFEC probe. Set the HFEC instrument to operate between 50 KHz and 75 KHz. If HFEC method indicates a crack, confirm a crack indication using magnetic particle inspec- tion. Refer to SOPM 20-20-01 as an accepted procedure. (b) An optional magnetic particle inspection can be used. Refer to SOPM 20-20-01 as an accepted procedure. (c) HFEC crack indications can be confirmed using the magnetic particle inspection. If crack indications are found with HFEC and could not be confirmed with magnetic particle inspection, the HFEC crack indication is a non relevant indication due to chrome cracking. FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 47 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 48 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT MAIN CARGO DOORWAY LOWER SILL LATCH PIN FITTING ASSEMBLY (8 LOCATIONS) (SHOWN WITH OPTIONAL CLIP LATCH PIN FITTING ASSEMBLY O LATCH PIN CROSS BOLT ASSEMBLY INSTALLED) 2403706 FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT (SHEET 1 OF 2) Original Issue: February 06, 2012 Revision 1 September 16, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3536 Work - See page 1 for details. 48 of 82 ### Page 49 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 this figure. More DataQtyIdentificationNameTaskStep -8NAS1303-22 (NAS1303-30 or NAS1103-29 or NAS1103-30 or NAS1303-29 optional) Latch Pin Cross BoltRemove1 Install with BMS 3- 27 corrosion inhibit- ing material. 8BACB30LM3-22 (BACB30LM3-24 option- al) Latch Pin Cross BoltInstall (New)2 FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 49 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 50 (OCR) BOEING SERVICE BULLETIN A3536 ALERT ALERT MAIN CARGO DOOR 12 CAM LATCH (8 LOCATIONS) A 2089735 FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT (SHEET 1 OF 3) Original Issue: February 06, 2012 Revision 1 September 16, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3536 Work - See page 1 for details. 50 of 82 ### Page 51 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 this figure. More DataQtyIdentificationNameTaskStep (a)169-23438-2Cam Latch 1Remove1 (a)1143N8060-1Cam Latch 2Remove (a)1143N8027-2Cam Latch 3Remove (a) Gusset must be removed to allow re- moval of cam latch number 4. 169-23439-3Cam Latch 4Remove (a)169-23439-4Cam Latch 5Remove (a)1143N8027-1Cam Latch 6Remove (a)1143N8060-2Cam Latch 7Remove (a)169-23438-1Cam Latch 8Remove FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT (SHEET 2 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 51 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 52 More DataQtyIdentificationNameTaskStep (a) (b) (d)169-23438-2Cam Latch 1Install (New)2 (a) (b) (c) (d)1143N8060-1Cam Latch 2Install (New) (a) (b) (d)1143N8027-2Cam Latch 3Install (New) (a) (b) (d) Gusset must be removed to allow installation of cam latch number 4. 169-23439-3Cam Latch 4Install (New) (a) (b) (d)169-23439-4Cam Latch 5Install (New) (a) (b) (d)1143N8027-1Cam Latch 6Install (New) (a) (b) (c) (d)1143N8060-2Cam Latch 7Install (New) (a) (b) (d)169-23438-1Cam Latch 8Install (New) (a) Part numbers and quantities necessary are based on inspection findings. (b) Use the original removed cam latch as a pattern/template to locate new cross bolt holes. Match hole an- gularity from existing cam latch. (c) Cam latch number 2 and cam latch number 7 only have two cross bolt holes. (d) It is acceptable to install a reworked Cam Latch with the same part number instead of a new part. FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 52 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 53 (OCR) BOEING SERVICE BULLETIN A3536 ALERT ALERT MAIN CARGO DOORWAY LOWER SILL RAD O D D LATCH PIN FITTING ASSEMBLY (8 LOCATIONS) 0.91* 0.89 LATCH PIN 13 LATCH PIN FITTING ASSEMBLY (SHOWN WITH OPTIONAL CLIP ASSEMBLY INSTALLED) WEAR PLATE 2403707 FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT (SHEET 1 OF 2) 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. 53 of 82 ### 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 this figure. More DataQtyIdentificationNameTaskStep -6-83137-2Latch PinRemove1 Install latch pin wet with BMS 3-27 corro- sion inhibiting materi- al on faying sur- faces. Make sure the latch pin extends out 0.90 inch +/-0.01 inch from the wear plate. -6-83137-2Latch PinInstall (New)2 FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 54 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 55 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT 00 G 00 C 3 C DO C 2403708 FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION (SHEET 1 OF 3) 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. 55 of 82 ### Page 56 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT LATCH PIN (8 LOCATIONS) CRITICAL AREA ENTIRE CIRCUMFERENCE O.: CRITICAL AREAS ENTIRE CIRCUMFERENCE WEAR PLATE CAM LATCH E 2403709 FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION (SHEET 2 OF 3) 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. 56 of 82 ### Page 57 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 this figure. More DataQtyIdentificationNameTaskStep (a) (b)169-23438-2Cam Latch 1Remove / Keep1 (a) (b)1143N8060-1Cam Latch 2Remove / Keep (a) (b)1143N8027-2Cam Latch 3Remove / Keep (a) (b) (c)169-23439-3Cam Latch 4Remove / Keep (a) (b)169-23439-4Cam Latch 5Remove / Keep (a) (b)1143N8027-1Cam Latch 6Remove / Keep (a) (b)1143N8060-2Cam Latch 7Remove / Keep (a) (b)169-23438-1Cam Latch 8Remove / Keep Detailed inspection of the cam latch for cracks or gouges in critical areas. (d) --Cam LatchInspect2 (a) (b) (e)169-23438-2Cam Latch 1Install (Kept)3 (a) (b) (e)1143N8060-1Cam Latch 2Install (Kept) (a) (b) (e)1143N8027-2Cam Latch 3Install (Kept) (a) (b) (e)169-23439-3Cam Latch 4Install (Kept) (a) (b) (e)169-23439-4Cam Latch 5Install (Kept) (a) (b) (e)1143N8027-1Cam Latch 6Install (Kept) (a) (b) (e)1143N8060-2Cam Latch 7Install (Kept) (a) (b) (e)169-23438-1Cam Latch 8Install (Kept) Detailed inspection of the latch pin for cracks or gouges in critical areas. 86-83137-2Latch PinInspect4 (a) It is important to identify the Cam Latch part locations to make sure the parts are installed in correct loca- tions. Cam latches installed incorrectly may seriously compromise proper door operation. (b) Part numbers and quantities necessary are based on inspection findings. (c) Gusset must be removed to allow removal of cam latch number 4. (d) Only inspect removed cam latch(es). (e) Do not install kept cam latch if cracked or gouged in critical areas. FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION (SHEET 3 OF 3) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 57 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 58 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT MAIN CARGO DOORWAY LOWER SILL RAD On F CROSS BOLT (8 LOCATIONS) 3 LATCH PIN (8 LOCATIONS) 1 CAM LATCH (8 LOCATIONS) 2403710 FIGURE 9: MAIN CARGO DOOR - CAM LATCHES, LATCH PINS AND LATCH PIN CROSS BOLTS INSPECTION (SHEET 1 OF 2) 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. 58 of 82 ### Page 59 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 this figure. More DataQtyIdentificationNameTaskStep General visual in- spection of the cam latch. (a) 169-23438-2Cam Latch 1Inspect1 General visual in- spection of the cam latch. (a) 1143N8060-1Cam Latch 2Inspect General visual in- spection of the cam latch. (a) 1143N8027-2Cam Latch 3Inspect General visual in- spection of the cam latch. (a) 169-23439-3Cam Latch 4Inspect General visual in- spection of the cam latch. (a) 169-23439-4Cam Latch 5Inspect General visual in- spection of the cam latch. (a) 1143N8027-1Cam Latch 6Inspect General visual in- spection of the cam latch. (a) 1143N8060-2Cam Latch 7Inspect General visual in- spection of the cam latch. (a) 169-23438-1Cam Latch 8Inspect General visual in- spection of the latch pins. (a) 86-83137-2Latch PinInspect2 General visual in- spection of the latch pin cross bolt. (a) 8-Cross BoltInspect3 (a) Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin cross bolts. FIGURE 9: MAIN CARGO DOOR - CAM LATCHES, LATCH PINS AND LATCH PIN CROSS BOLTS INSPECTION (SHEET 2 OF 2) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536Revision 1 September 16, 2015 59 of 82 BOEING SERVICE BULLETIN A3536 ALERTALERT ### Page 60 (OCR) BOEING SERVICE BULLETIN А3536 ALERT ALERT D MECHANISM CENTER LATCH D LATCH FORWARD MECHANISM AFT LATCH MECHANISM D NO. 1 NO. 2 NO. 4 B NO. 3 B NO. 6 B NO. 5 B NO. 8 NO. 7 B 2089749 FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING (SHEET 1 OF 3) Original Issue: February 06, 2012 Revision 1 September 16, 2015 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3536 Work - See page 1 for details. 60 of 82 The text continues at https://openairdocs.org/service-documents/boeing/a3536/file/306691e7ba93.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.