Boeing SB A3536: Revision 1, text

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Commercial Airplanes 707 Service Bulletin ALERT Number: A3536 Original Issue: February 06, 2012 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 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2012 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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 A3536 1 of 76

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Original Issue: February 06, 2012 A3536 2 of 76 BOEING SERVICE BULLETIN A3536

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Table of Contents

Summary5

1. PLANNING INFORMATION9

A. Effectivity9

1. Airplanes9

2. Spares Affected ........................................ 1 1 B. Concurrent Requirements ...................................... 1 1 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 3 F. Approval ............................................... 2 2 G. Manpower .............................................. 2 2 H. Weight and Balance Changes .................................... 2 3 I. Electrical Load Data ......................................... 2 3 J. References .............................................. 2 4

1. Existing Data .......................................... 2 4

2. Data supplied with this Service Bulletin ............................ 2 4

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 4 K. Publications Affected ........................................ 2 4 L. Interchangeability and Intermixability of Parts ........................... 2 4

2. MATERIAL INFORMATION ........................................ 2 5 A. Material - Price and Availability ................................... 2 5 B. Industry Support Information .................................... 2 5 C. Parts Necessary For Each Airplane ................................. 2 5

1. Kits/Parts ............................................ 2 5

2. Parts and Materials Supplied by the Operator ........................ 2 5

3. Parts Modified and Reidentified ................................ 2 6

4. Parts Removed and Not Replaced .............................. 2 6 D. Parts Necessary to Change Spares ................................. 2 6 E. Special Tooling - Price and Availability ............................... 2 6 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 7

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 0 FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION ......... 3 5 FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT ..... 3 8 FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT ............ 4 0 FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION ........ 4 2 FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT ........... 4 4 FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT ................... 4 6 FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT .................... 4 8 FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION ........... 5 0 FIGURE 9: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION ......... 5 2 FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING ............. 5 4 FIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT . . 57 APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST ......................... 5 9

Original Issue: February 06, 2012 A3536 3 of 76 BOEING SERVICE BULLETIN A3536

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Original Issue: February 06, 2012 A3536 4 of 76 BOEING SERVICE BULLETIN A3536

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Commercial Airplanes 707 Service Bulletin ALERT SummaryNumber: A3536Original Issue: February 06, 2012 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 wear and the latch pins are inspected for migration. The inspections are necessary in order to find and replace worn cam latches, latch pins and latch pin attachment bolts. If not replaced, worn cam latches, latch pins and latch pin attachment 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 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 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. In addition, the cross bolt that attaches the latch pin had signs of corrosion on the fracture surfaces.

Original Issue: February 06, 2012 A3536 5 of 76

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If the 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 this 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 lead 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.

Accomplishment of the work given in this service bulletin will make sure the cam latches, latch pins and latch pins cross bolts are inspected and replaced if wear is found. The MCD will also be re-rigged to the requirements for door flushness, cam latch/latch pin concentricity, latch pin fitting forward/aft gap and shim thickness.

Boeing Service Related Problem (SRP) 707-SRP-52-0088 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., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications 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 Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin YesSpecial Tooling Required ACTION Get access to the MCD. Do a detailed inspection of the cam latches and latch pins. Check the torque of 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. Do a High Frequency Eddy Current (HFEC) or magnetic particle inspection of cam latch 1 and cam latch 2 for signs of cracks. Replace any cracked or broken parts. Rig the MCD to the requirements for door flushness, cam latch/latch pin concentricity, latch pin fitting forward/aft gap and shim thickness. Do the latch mechanism adjustment test and post-rigging inspections in accordance with this service bulletin.

EFFECTIVITY 707-300, 707-300B and 707-300C airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

Original Issue: February 06, 2012 A3536 6 of 76 BOEING SERVICE BULLETIN A3536

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COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the 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

Original Issue: February 06, 2012 A3536 7 of 76 BOEING SERVICE BULLETIN A3536

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BOEING SERVICE BULLETIN A3536

ALERT ALERT

MAIN CARGO DOORWAY

LOWER SILL ∞ D ED O

LATCH PIN

- DO A DETAILED INSPECTION OF THE CAM LATCHES AND LATCH PINS.

CHECK THE TORQUE OF THE 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 CROSS BOLTS.

- DO A HFEC OR MAGNETIC PARTICLE INSPECTION OF CAM LATCH 1 AND CAM LATCH 2 FOR SIGNS OF CRACKS.

- RIG THE MCD IN ACCORDANCE WITH THE REQUIREMENTS FOR DOOR

FLUSHNESS, CAM LATCH/LATCH PIN CONCENTRICITY, LATCH PIN FITTING FORWARD/AFT GAP AND SHIM THICKNESS.

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Commercial Airplanes 707 Service Bulletin ALERT Number: A3536 Original Issue: February 06, 2012 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, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

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

Original Issue: February 06, 2012 A3536 9 of 76

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GroupVariable Number 107181 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

Original Issue: February 06, 2012 A3536 10 of 76 BOEING SERVICE BULLETIN A3536

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GroupVariable Number 108451 - 08452 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.Boeing

(a) The work given in Boeing Service Bulletin 707-3477 Revision 2 is necessary to comply with FAA Airworthiness Directive AD 91-22-04.

Original Issue: February 06, 2012 A3536 11 of 76 BOEING SERVICE BULLETIN A3536

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C. Reason Accomplishment of the inspections in this service bulletin will make sure the Main Cargo Door (MCD) cam latches are inspected for wear and the latch pins are inspected for migration. The inspections are necessary in order to find and replace worn cam latches, latch pins and latch pin attachment bolts. If not replaced, worn cam latches, latch pins and latch pin attachment 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.

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.

Boeing Service Related Problem (SRP) 707-SRP-52-0088 is related to this service bulletin.

Original Issue: February 06, 2012 A3536 12 of 76 BOEING SERVICE BULLETIN A3536

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