# Boeing Service Bulletin A3536: Revision 1

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- Document: [Boeing Service Bulletin A3536](https://openairdocs.org/service-documents/boeing/a3536.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin - 707-A3536-00
- Pages: 76
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## Text

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### Page 1

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Unpublished Work - All Rights Reserved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.
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Table of Contents
Summary ...................................................... 5
1. PLANNING INFORMATION ........................................ 9
A. Effectivity ................................................ 9
1. Airplanes ............................................. 9
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
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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.
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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 Ap-
proved 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.
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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
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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.
CAM LATCH
2089398
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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
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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
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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.
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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.
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.
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.
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D. Description
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 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.
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.
Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door
(MCD)
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 detailed inspection
of the cam latches and
latch pins in accordance
with Accomplishment In-
struction 3.B.1.b.
All airplanes
AND
Torque the cross bolts in
the latch pins in accor-
dance with Accomplish-
ment Instruction 3.B.1.c.
AND
Measure the extension of
the latch pins in accor-
dance with Accomplish-
ment Instruction 3.B.1.d.
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Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door
(MCD)
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
-Before further flight.Replace all cracked or
broken part(s) and re-
place all alloy steel cross
bolts through the latch
pins with Corrosion Resis-
tant Steel (CRES) cross
bolts in accordance with
Accomplishment Instruc-
tion 3.B.2.a.
Inspection Condition 1 - If
the inspections reveal one
or more of the following:
1. Cracked or bro-
ken cam
latch(es).
2. Cracked or bro-
ken latch pin(s).
3. Broken latch pin
cross bolt(s).
AND
-Before further flight.Unless replaced with new
parts, do a High Frequen-
cy Eddy Current (HFEC)
or magnetic particle in-
spection of cam latch 1
and cam latch 2 in accor-
dance with Accomplish-
ment Instruction 3.B.2.b.
AND
-Before further flight.Rig the MCD and do the
latch mechanism adjust-
ment test in accordance
with Accomplishment In-
struction 3.B.2.c.
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Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door
(MCD)
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
-Within 150 days
after the initial
inspection.
Within 330 flight
cycles after the
initial inspection.
Contact Boeing for re-
work instructions and do
the rework instructed by
Boeing in accordance
with Accomplishment In-
struction 3.B.3.a.
Inspection Condition 2 - If
the inspections reveal one
or more of the following:
1. Local deformation
of the cam latch
lip.
2. Flaking of the
chrome plating on
the cam latch or
latch pin.
3. Wear of the
chrome plating
down to the base
material of the
cam latch or latch
pin.
AND
Replace all cam latches
and latch pins in accor-
dance with Accomplish-
ment Instruction 3.B.3.b.
AND
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 cam latches and
latch pins in accordance
with Accomplishment In-
struction 3.B.3.c.
AND
-Within 24
months after the
original issue
date of this ser-
vice bulletin.
Within 3000
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Do a HFEC or magnetic
particle inspection of cam
latch 1 and cam latch 2 in
accordance with Accom-
plishment Instruction
3.B.3.d.
AND
Replace all alloy steel
cross bolts through the
latch pins with CRES
cross bolts in accordance
with Accomplishment In-
struction 3.B.3.e.
AND
Rig the MCD and do the
latch mechanism adjust-
ment test in accordance
with Accomplishment In-
struction 3.B.3.f.
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Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door
(MCD)
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
-Before further flight.Contact Boeing for addi-
tional inspection and/or
repair instructions and do
the inspection and/or re-
pair in accordance with
the Boeing instructions in
accordance with Accom-
plishment Instructions
3.B.4.a.
Inspection Condition 3 - If
the initial inspections reveal
one or more signs of the
following:
1. Corrosion of the
cam latch or latch
pin.
2. Gouges and/or
scrapes in the
cam latch or latch
pin chrome plat-
ing or base mate-
rial.
3. Deformations of
the cam latch or
latch pin.
4. Any other dam-
age not identified
in Inspection
Conditions 1 and
2.
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Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door
(MCD)
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
-Within 150 days
after the initial
inspection.
Within 330 flight
cycles after the
initial inspection.
Replace the latch pin in
accordance with Accom-
plishment Instruction
3.B.5.a.(1).
Inspection Condition 4.1 -
If the latch pin extension is
less than 0.84 inches or
greater than 0.94 inches.
AND
Remove the mating cam
latch and do a detailed
inspection in accordance
with Accomplishment In-
struction 3.B.5.a.(2).
AND
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 general visual in-
spection of the cam
latches and latch pins for
broken, cracked, deforma-
tions, flaking or wear of
the chrome plating in ac-
cordance with Accom-
plishment Instruction
3.B.5.a.(3).
AND
-Within 24
months after the
original issue
date of this ser-
vice bulletin.
Within 3000
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Do a HFEC or magnetic
particle inspection of cam
latch 1 and cam latch 2 in
accordance with Accom-
plishment Instruction
3.B.5.a.(4).
AND
Replace all alloy steel
cross bolts through the
latch pins with CRES
cross bolts in accordance
with Accomplishment In-
struction 3.B.5.a.(5).
AND
Rig the MCD and do the
latch mechanism adjust-
ment test in accordance
with Accomplishment In-
struction 3.B.5.a.(6).
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Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door
(MCD)
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 cam latches and
latch pins in accordance
with Accomplishment In-
struction 3.B.5.b.(1).
Inspection Condition 4.2 -
If the latch pin extension is
greater than or equal to
0.84 inches and less than
or equal to 0.89 inches or
greater than or equal to
0.91 inches and less than
or equal to 0.94 inches.
AND
-Within 24
months after the
original issue
date of this ser-
vice bulletin.
Within 3000
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Do a HFEC or magnetic
particle inspection of cam
latch 1 and cam latch 2 in
accordance with Accom-
plishment Instruction
3.B.5.b.(2).
AND
Replace all alloy steel
cross bolts through the
latch pins with CRES
cross bolts in accordance
with Accomplishment In-
struction 3.B.5.b.(3).
AND
Rig the MCD and do the
latch mechanism adjust-
ment test in accordance
with Accomplishment In-
struction 3.B.5.b.(4).
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Table 1: Initial (Pre-Rigging) Inspections of the Cam Latches and Latch Pins for the Main Cargo Door
(MCD)
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 general visual in-
spection in accordance
with Accomplishment In-
struction 3.B.6.a.
Inspection Condition 5 - If
the inspections reveal no
signs of damage, distress
or incorrect rigging as de-
scribed in Inspection Condi-
tions 1 through 4. AND
3000 flight cycles
or 24 months
(whichever occurs
first). (a)
24 months after
the initial inspec-
tion.
Within 3000
flight cycles af-
ter the initial in-
spection.
Do a detailed inspection
of the cam latches and
latch pins in accordance
with Accomplishment In-
struction 3.B.6.b.
AND
Do a HFEC or magnetic
particle inspection of cam
latch 1 and cam latch 2 in
accordance with Accom-
plishment Instruction
3.B.6.c
AND
-Within 48
months after the
original issue
date of this ser-
vice.
Within 6000
flight cycles af-
ter the original
issue date of
this service bul-
letin.
Replace all alloy steel
cross bolts through the
latch pins with CRES
cross bolts in accordance
with Accomplishment In-
struction 3.B.6.d.
AND
Rig the MCD and do the
latch mechanism adjust-
ment test in accordance
with Accomplishment In-
struction 3.B.6.e.
(a) Accomplishment of the MCD rig and the latch mechanism adjustment test in accordance with Accomplish-
ment Instruction 3.B.2.c. or 3.B.3.f. or 3.B.5.a.(6) or 3.B.5.b.(4) or 3.B.6.e. terminates repeat inspections.
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Table 2: Repetitive Post-Rigging Inspections of the Cam Latches and Latch Pins for the Main Cargo
Door (MCD)
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
330 flight cycles or
150 days
(whichever occurs
first).
Within 150 days
after the MCD
rig.
Within 330 flight
cycles after the
MCD rig.
Do a general visual in-
spection in accordance
with Accomplishment In-
struction 3.B.7.a.(1).
All airplanes that have
completed the MCD rig in
accordance with Accom-
plishment Instruction
3.B.2.c. or 3.B.3.f. or
3.B.5.a.(6) or 3.B.5.b.(4) or
3.B.6.e.
AND
3000 flight cycles
or 24 months
(whichever occurs
first).
Within 24
months after the
MCD rig.
Within 3000
flight cycles af-
ter the MCD rig.
Do a detailed inspection
of the cam latches and
latch pins in accordance
with Accomplishment In-
struction 3.B.7.a.(2).
AND
6000 flight cycles
or 48 months
(whichever occurs
first).
Within 48
months after the
MCD rig.
Within 6000
flight cycles af-
ter the MCD rig.
Do a HFEC or magnetic
particle inspection of cam
latch 1 and cam latch 2 in
accordance with Accom-
plishment Instruction
3.B.7.a.(3).
-Before further flight.Replace all cracked or
broken part(s) in accor-
dance with Accomplish-
ment Instruction
3.B.7.b.(1).
Post-rigging Inspection
Condition 1 - If the inspec-
tions reveal one or more of
the following:
1. Cracked or bro-
ken cam
latch(es).
2. Cracked or bro-
ken latch pin(s).
3. Broken latch pin
cross bolt(s).
AND
-Before further flight.Unless replaced with new
parts, do a HFEC or
magnetic particle inspec-
tion of cam latch 1 and
cam latch 2 in accor-
dance with Accomplish-
ment Instruction
3.B.7.b.(2).
AND
-Before further flight.Rig the MCD and do the
latch mechanism adjust-
ment test in accordance
with Accomplishment In-
struction 3.B.7.b.(3).
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Table 2: Repetitive Post-Rigging Inspections of the Cam Latches and Latch Pins for the Main Cargo
Door (MCD)
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
-Within 150 days
after the post-
rigging inspec-
tion.
Within 330 flight
cycles after the
post-rigging in-
spection.
Contact Boeing for re-
work instructions and do
the rework instructed by
Boeing in accordance
with Accomplishment In-
struction 3.B.7.c.(1).
Post-rigging Inspection
Condition 2 - If the inspec-
tions reveal one or more of
the following:
1. Local deformation
of the cam latch
lip.
2. Flaking of the
chrome plating on
the cam latch or
latch pin.
3. Wear of the
chrome plating
down to the base
material of the
cam latch or latch
pin.
AND
Replace all cam latches
and latch pins in accor-
dance with Accomplish-
ment Instruction
3.B.7.c.(2).
AND
330 flight cycles or
150 days
(whichever occurs
first).
Within 150 days
after the post-
rigging inspec-
tion.
Within 330 flight
cycle after the
post-rigging in-
spection.
Do a detailed inspection
of the remaining cam
latches and latch pins in
accordance with Accom-
plishment Instruction
3.B.7.c.(3).
AND
-Within 24
months after the
post-rigging in-
spection.
Within 3000
flight cycles af-
ter the post-rig-
ging inspection.
Do a HFEC or magnetic
particle inspection of cam
latch 1 and cam latch 2 in
accordance with Accom-
plishment Instruction
3.B.7.c.(4).
AND
Rig the MCD and do the
latch mechanism adjust-
ment test in accordance
with Accomplishment In-
struction 3.B.7.c.(5).
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Table 2: Repetitive Post-Rigging Inspections of the Cam Latches and Latch Pins for the Main Cargo
Door (MCD)
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever
Occurs First)
ActionCondition
-Before further flight.Contact Boeing for addi-
tional inspection and/or
repair instructions and do
the inspection and/or re-
pair in accordance with
the Boeing instructions in
accordance with Accom-
plishment Instruction
3.B.7.d.(1).
Post-rigging Inspection
Condition 3 - If the inspec-
tions reveal one or more
signs of the following:
1. Corrosion of the
cam latch or latch
pin.
2. Gouges and/or
scrapes in the
cam latch or latch
pin chrome plat-
ing or base mate-
rial.
3. Deformations of
the cam latch or
latch pin.
4. Any other dam-
age not identified
in Inspection
Conditions 1 and
2.
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.
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:
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 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 - FIGURE
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 inspections.
(f) Does not include time to match drill cam shaft.
(g) Does not include time to match drill latch pin
(h) Does not include inspection time
(i) Cam latch 4 will require 2 hours and a second person to remove.
H. Weight and Balance Changes
None.
I. Electrical Load Data
Not changed.
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J. References
1. Existing Data
a. Boeing Service Bulletin 707-3477.
b. Boeing Service Related Problem (SRP) 707-SRP-52-0088.
c. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 91-22-04.
d. Standard Overhaul Practices Manual (SOPM) 20-20-01.
e. 707 Aircraft Maintenance Manual (AMM) 52-11-0.
f. 707 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00.
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
SILL INSTL - LOWER, MAIN CARGO DOOR65-25343
LATCH PIN FITTING - ASSY65-25771
CAM - LATCH MECHANISM CARGO DOOR69-23438
BODY INSTALLATION - SECTION 4350-2543
These drawings were 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
None.
L. Interchangeability and Intermixability of Parts
Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.
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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
NotesNameQTYPart Number /
Specification
(a) (b)BOLT, HEX HEAD, 160 KSI MIN
TENSILE, LONG THREAD, A286,
NONLOCKING
8BACB30LM3-24
OR
BACB30LM3-22
Parts are only needed
if existing part cannot
be reworked. (c)
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
Sealant
5 oz.BMS 5-95, TYPE
1, CLASS B 1/2
(e)Flexbar ReproRubber Quicksetting
Putty or equivalent
8 oz-
(f)Rod, 3/16 diameter, 2 inches long1-
(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.
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NotesNameQTYPart Number /
Specification
(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 AP-
PENDIX A.
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 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
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPON-
DER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFOR-
MATION
Purchase Data:
Unit Price as of the Original
Issue date of this Service
Bulletin (US Dollars)
NameTool Kit Number
8,821.00Pin Set - Rigging, Main Deck, Main Cargo
Door
B52029-1
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Rental Data
Daily Price as of the Original
Issue date of this service
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 DoorB52029-1
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### Page 29

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
– Torque limits to tighten nuts and bolts are in 707 SRM, Chapter 51
4. Use the approved fastener and process material substitutions in accordance with
707 SRM, Chapter 51. Alternate fasteners are listed in 707 SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet the
installation standards in SRM Chapter 51, then a fastener of the same specification,
or an approved substitute, with a length which meets the installation standards in
SRM Chapter 51 may be used.
6. 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.
7. 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 ensure visual access to all surfaces in the
inspection area. This level of inspection is made under normal 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.
8. 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.
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B. WORK INSTRUCTIONS
NOTE: It is important to do the following steps in the specified order.
1. Initial Inspections
a. Open the Main Cargo Door to get access to the cam latches and latch pins. Refer to 707 AMM
52-11-01 as an accepted procedure.
b. Do a detailed inspection of the cam latches and latch pins in accordance with FIGURE 1.
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.
2. Inspection Condition 1:
If the inspections reveal one or more signs of the following:
– Cracked or broken cam latch(es)
– Cracked or broken latch pin(s)
– Broken latch pin cross bolt(s)
a. Replace cam latch in accordance with FIGURE 6, replace latch pin in accordance with FIGURE
7 and replace latch pin cross bolts with CRES cross bolts in accordance with FIGURE 5.
b. Unless replaced with new parts, do a High Frequency Eddy Current (HFEC) or magnetic
particle inspection of cam latch 1 and cam latch 2 for signs of cracks in accordance with
FIGURE 4. Address the inspection findings as described in Inspection Condition 1.
c. Rig the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11 and do the latch
mechanism adjustment test in accordance with APPENDIX A.
3. Inspection Condition 2:
If the inspections reveal one or more signs of the following:
– Local deformation of the cam latch lip
– Flaking of the chrome plating on the cam latch or latch pin
– Wear of the chrome plating down to the base material of the cam latch or latch pin
a. Contact Boeing for rework instructions and do the rework instructed by Boeing.
NOTE: Boeing recommends the operator provide a detailed description of the cam latch
deformations (including size and location, as well as the total number of flights the
cam latch has been in service) so that Boeing has time to determine rework
instructions and the operator has time to organize the resources needed to complete
the changes within the applicable compliance period.
b. Replace all cam latches and latch pins with signs of flaking of the chrome plating or wear
down to the base material in accordance with FIGURE 6 and FIGURE 7.
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c. Do a detailed inspection of the cam latches and latch pins in accordance with FIGURE 1.
Address the inspection findings as described in Inspection Conditions 1 through 4.
d. Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for signs of cracking
in accordance with FIGURE 4. Address the inspection findings as described in Inspection
Condition 1.
e. Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance
with FIGURE 5.
f. Rig the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11 and do the latch
mechanism adjustment test in accordance with APPENDIX A.
4. Inspection Condition 3:
If the inspections reveal one or more signs of the following:
– Corrosion of the cam latch or latch pin
– Gouges and/or scrapes in the cam latch or latch pin chrome plating or base material
– Deformations of the cam latch or latch pin
– Any other damage not identified in Inspection Conditions 1 and 2.
a. Contact Boeing for additional inspection and/or repair instructions and do the applicable
inspection and/or repair in accordance with the Boeing instructions.
NOTE: Boeing recommends the operator provide a detailed description of the inspection
findings (including photographs if possible).
5. Inspection Condition 4:
a. Inspection Condition 4.1 - If the latch pin extension is less than 0.84 inches or greater than
0.94 inches:
(1) Replace the latch pin in accordance with FIGURE 7.
(2) Remove the mating cam latch and do a detailed inspection in accordance with FIGURE
8. Address the inspection findings as described in Inspection Condition 1.
(3) Do a general visual inspection of the cam latches and latch pins in accordance with
FIGURE 9. Address the inspection findings as described in Inspection Condition 1.
(4) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for signs of
cracking in accordance with FIGURE 4. Address the inspection findings as described in
Inspection Condition 1.
(5) Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in
accordance with FIGURE 5.
(6) Rig the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11 and do the
latch mechanism adjustment test in accordance with APPENDIX A.
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b. Inspection Condition 4.2 - If the latch pin extension is greater than or equal to 0.84 inches and
less than or equal to 0.89 inches or greater than or equal to 0.91 inches and less than or equal
to 0.94 inches:
(1) Do a detailed inspection of the cam latches and latch pins in accordance with FIGURE
1. Address the inspection findings as described in Inspection Conditions 1 through 3.
(2) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for signs of
cracking in accordance with FIGURE 4. Address the inspection findings as described in
Inspection Condition 1.
(3) Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in
accordance with FIGURE 5.
(4) Rig the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11 and do the
latch mechanism adjustment test in accordance with APPENDIX A.
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 originally in condition 4.2 with 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 latch pin with BMS 5-95
sealant and install pin with BMS 3-27 corrosion inhibiting compound.
6. Inspection Condition 5:
If the inspections reveal no signs of damage, distress, or incorrect rigging as described in Inspection
Conditions 1 through 4:
a. Do a general visual inspection of the cam latches and latch pins in accordance with FIGURE
9. Address the inspection findings as described in Inspection Condition 1.
b. Do a detailed inspection of the cam latches and latch pins in accordance with FIGURE 1.
Address the inspection findings as described in Inspection Conditions 1 through 5.
c. Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for signs of cracking
in accordance with FIGURE 4. Address the inspection findings as described in Inspection
Condition 1.
d. Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance
with FIGURE 5.
e. Rig the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11 and do the latch
mechanism adjustment test in accordance with APPENDIX A.
7. Post-Rigging Inspections for Airplanes that have completed the Main Cargo Door rig in accordance
with FIGURE 10 and FIGURE 11:
a. Post-Rigging Inspection of all airplanes:
(1) Do a general visual inspection of the cam latches and latch pins in accordance with
FIGURE 9. Address the inspection findings as described in Post-Rigging Inspection
Condition 1.
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### Page 33

(2) Do a detailed inspection of the cam latches and latch pins in accordance with FIGURE
1. Address the inspection findings as described in Post-Rigging Inspection Conditions 1
through 3.
(3) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for signs of
cracking in accordance with FIGURE 4. Address the inspection findings as described in
Post-Rigging Inspection Condition 1.
b. Post-rigging Inspection Condition 1:
If the post-rigging inspections reveal one or more of the following:
– Cracked or broken cam latch(es)
– Cracked or broken latch pin(s)
– Broken latch pin cross bolt(s)
(1) Replace cam latch in accordance with FIGURE 6, replace latch pin in accordance with
FIGURE 7 and replace latch pin cross bolt in accordance with FIGURE 5.
(2) Unless replaced with new parts, do a HFEC or magnetic particle inspection of cam latch
1 and cam latch 2 for signs of cracks in accordance with FIGURE 4. Address the inspection
findings as described in Post-Rigging Inspection Condition 1.
(3) Rig the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11 and do the
latch mechanism adjustment test in accordance with APPENDIX A.
c. Post-rigging Inspection Condition 2:
If the post-rigging inspections reveal one or more of the following:
– Local deformation of the cam latch lip
– Flaking of the chrome plating on the cam latch or latch pin
– Wear of the chrome plating down to the base material of the cam latch or latch pin
(1) Contact Boeing for rework instructions and do the rework instructed by Boeing.
NOTE: Boeing recommends the operator provide a detailed description of the cam latch
deformations (including size and location, as well as the total number of flights
the cam latch has been in service) so that Boeing has time to determine rework
instructions and the operator has time to organize the resources needed to
complete the changes within the applicable compliance period.
(2) Replace all cam latches and latch pins with signs of flaking of the chrome plating or wear
down to the base material in accordance with FIGURE 6 and FIGURE 7.
(3) Do a detailed inspection of the cam latches and latch pins in accordance with FIGURE
1. Address the inspection findings as described in Post-Rigging Inspection Conditions 1
through 3.
(4) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for signs of
cracking in accordance with FIGURE 4. Address the inspection findings as described in
Inspection Condition 1.
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### Page 34

(5) Rig the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11 and do the
latch mechanism adjustment test in accordance with APPENDIX A.
d. Post-rigging Inspection Condition 3:
If the post-rigging inspections reveal one or more of the following:
– Corrosion of the cam latch or latch pin
– Gouges and/or scrapes in the cam latch or latch pin chrome plating or base material
– Deformations of the cam latch or latch pin
– Any other damage not identified in Inspection Conditions 1 and 2.
(1) Contact Boeing for additional inspection and/or repair instructions and do the applicable
inspection and/or repair in accordance with the Boeing instructions.
NOTE: Boeing recommends the operator provide a detailed description of the inspection
findings (including photographs if possible).
8. Put the airplane back to a serviceable condition.
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BOEING SERVICE BULLETIN А3536
ALERT  ALERT
(6) C  (5) C
C
2089401
FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION
(SHEET 1 OF 3)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN А3536
ALERT  ALERT
LATCH PIN
(8 LOCATIONS)
(9)
POTENTIAL
CRACKING AREA
CHROME WEAR
THROUGH
GOUGES
POTENTIAL
CRACKING AREAS
CAM LATCH  CHROME WEAR
THROUGH
GOUGES
PROTRUDING LIP ON
EDGE OF CAM HEAD
2089729
FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION
(SHEET 2 OF 3)
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### Page 37

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 1Inspect1
(a) (c)1143N8060-1Cam Latch 2Inspect2
(a) (c)1143N8027-2Cam Latch 3Inspect3
(a)169-23439-3Cam Latch 4Inspect4
(a)169-23439-4Cam Latch 5Inspect5
(a) (c)1143N8027-1Cam Latch 6Inspect6
(a) (c)1143N8060-2Cam Latch 7Inspect7
(a)169-23438-1Cam Latch 8Inspect8
(b)86-83137-2Latch PinInspect9
(a) Do a detailed inspection of the cam latch for damage, distress or incorrect rigging. Some examples of
damage or distress are: broken parts, cracks, deformations, flaking of the chrome plating, wear of the
chrome plating down to the base material, corrosion, chips, gouges etc.
(b) Do a detailed inspection of the latch pin for signs of damage, distress or incorrect rigging. Some examples
are: broken parts, cracks, deformations, flaking of the chrome plating, wear of the chrome plating down
to the base material, corrosion, chips, gouges etc
(c) Cam Latches 2, 3, 6 and 7 are not chromed, therefore chrome flaking and chrome wear through cannot
be assessed at these locations. Check for excessive wear.
FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION
(SHEET 3 OF 3)
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### Page 38 (OCR)

BOEING SERVICE BULLETIN А3536
ALERT  ALERT
MAIN CARGO DOORWAY
LOWER SILL
LATCH PIN FITTING
ASSEMBL
(8 LOCATIONS)
LATCH PIN FITTING ASSEMBLY  O BOLT
(SHOWN WITH OPTIONAL CLIP
ASSEMBLY INSTALLED)
2089730
FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT
(SHEET 1 OF 2)
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### Page 39

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-BoltTorque1
(a) Make sure the cross bolt is capable of reacting 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 the integrity
of the cross bolt.
FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT
(SHEET 2 OF 2)
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### Page 40 (OCR)

BOEING SERVICE BULLETIN А3536
ALERT  ALERT
MAIN CARGO DOORWAY
LOWER SILL
LATCH PIN FITTING
ASSEMBLY
(8 LOCATIONS)
0.91
0.89
LATCH PIN FITTING ASSEMBLY
(SHOWN WITH OPTIONAL CLIP
ASSEMBLY INSTALLED)
FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT
(SHEET 1 OF 2)
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### 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
Make sure the latch pin extends
out 0.90 inch +/- 0.01 inch from
the wear plate.
8-Latch PinMeasure1
FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN А3536
ALERT  ALERT
120
WD
CAM LATCH
(3) INSPECTION AREA
2089732
FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION
(SHEET 1 OF 2)
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### 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
-169-23438-2Cam Latch 1Remove / Keep1
-1143N8060-1Cam Latch 2Remove / Keep2
(a) (b) (c) (d)169-23438-2Cam Latch 1Inspect3
(a) (b) (c) (d)1143N8060-1Cam Latch 2Inspect
-169-23438-2Cam Latch 1Install (Kept)4
-1143N8060-1Cam Latch 2Install (Kept)5
(a) Do a High Frequency Eddy Current (HFEC) inspection of the cam latch for cracking in accordance with
707 NDT Part 6, 51-00-00 Figure 13 or Figure 24
(b) 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 using magnetic particle inspection. Refer
to SOPM 20-20-01 as an accepted procedure.
(c) A magnetic particle inspection can be used as an alternative to the HFEC inspection or to confirm crack
indications from the HFEC inspections. Refer to SOPM 20-20-01 as an accepted procedure.
(d) 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)
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BOEING SERVICE BULLETIN А3536
ALERT  ALERT
MAIN CARGO DOORWAY
LOWER SILL
LATCH PIN FITTING
ASSEMBL
(8 LOCATIONS)
LATCH PIN FITTING ASSEMBLY  13 BOLT
(SHOWN WITH OPTIONAL CLIP
ASSEMBLY INSTALLED)
2089734
FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT
(SHEET 1 OF 2)
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### 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
-8-BoltRemove1
If installed.8143N8157-2Clip AssemblyRemove / Keep2
(a) (b)8BACB30LM3-24 OR
BACB30LM3-22
BoltInstall (New)3
(b)8143N8157-2Clip AssemblyInstall (Kept)
(a) Install with BMS 3-27 corrosion inhibiting compound on faying surfaces.
(b) Installation of 143N8157-2 clip assembly is optional. Use a BACB30LM3-24 bolt if clip assembly is installed.
Use a BACB30LM3-22 bolt if clip assembly is not installed.
FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT
(SHEET 2 OF 2)
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### Page 46 (OCR)

BOEING SERVICE BULLETIN A3536
ALERT  ALERT
MAIN CARGO DOOR
2) CAM LATCH  (8 LOCATIONS) LA
FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT
(SHEET 1 OF 2)
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### 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
Gusset must be re-
moved to allow re-
moval of cam latch
number 4.
--Cam LatchRemove1
(a) (b) (c)--Cam LatchInstall (New)2
(a) Use the original removed cam latch as a pattern/template to locate new cross bolt holes. Match hole an-
gularity from existing cam latch.
(b) Cam latch number 2 and cam latch number 7 only have two cross bolt holes.
(c) There is a possibility the cam latch can be refinished with new chrome plating. Before a cam latch or latch
pin can be reused, the operator must provide Boeing with a detailed description of the chrome damage,
including size and location, as well as the total number of flights the cam latch or latch pin has been in
service. Boeing will use this information to determine if the cam latch or latch pin can be refinished and
reused.
FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT
(SHEET 2 OF 2)
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### Page 48 (OCR)

BOEING SERVICE BULLETIN A3536
ALERT  ALERT
MAIN CARGO DOORWAY
LOWER SILL
LATCH PIN FITTING
ASSEMBLY
(8 LOCATIONS)
LATCH PIN 1X
LATCH PIN FITTING ASSEMBLY
(SHOWN WITH OPTIONAL CLIP
ASSEMBLY INSTALLED)
FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT
(SHEET 1 OF 2)
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### 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
---Latch PinRemove1
Install latch pin wet
with BMS 3-27 corro-
sion compound on
faying surfaces. (a)
-6-83137-2Latch PinInstall (New)2
(a) There is a possibility the latch pin can be refinished with new chrome plating. Before a cam latch or latch
pin can be reused, the operator must provide Boeing with a detailed description of the chrome damage,
including size and location, as well as the total number of flights the cam latch or latch pin has been in
service. Boeing will use this information to determine if the cam latch or latch pin can be refinished and
reused.
FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT
(SHEET 2 OF 2)
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BOEING SERVICE BULLETIN А3536
ALERT  ALERT
13 в
З В
0З В
3) В  INED  2089738
FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION
(SHEET 1 OF 2)
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### 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) (b)--Cam LatchRemove1
Do a detailed inspection of
the cam latch for cracking.
--Cam LatchInspect2
(a)--Cam LatchInstall (Kept)3
(a) Identify the Cam Latch part locations to make sure the parts are re-installed in correct locations. Cam
latches installed incorrectly may seriously compromise proper door operation.
(b) Gusset must be removed to allow removal of cam latch number 4.
FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION
(SHEET 2 OF 2)
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### Page 52 (OCR)

BOEING SERVICE BULLETIN А3536
ALERT  ALERT
MAIN CARGO DOORWAY
LOWER SILL
2) LATCH PIN
(8 LOCATIONS)
1) CAM LATCH
(8 LOCATIONS)
FWD
2089748
FIGURE 9: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION
(SHEET 1 OF 2)
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### Page 53

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 1Inspect1
(a)1143N8060-1Cam Latch 2Inspect
(a)1143N8027-2Cam Latch 3Inspect
(a)169-23439-3Cam Latch 4Inspect
(a)169-23439-4Cam Latch 5Inspect
(a)1143N8027-1Cam Latch 6Inspect
(a)1143N8060-2Cam Latch 7Inspect
(a)169-23438-1Cam Latch 8Inspect
(a)86-83137-2Latch PinInspect2
(a) Do a general visual inspection of the cam latch for broken, cracked, missing or migrated parts.
FIGURE 9: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION
(SHEET 2 OF 2)
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### Page 54 (OCR)

BOEING SERVICE BULLETIN А3536
ALERT  ALERT
D  I CENTER LATCH  MECHANISM
o
FORWARD
LATCH
MECHANISM
AFT LATCH
MECHANISM
NO. 1
NO. 2
NO.4 B  NO. 3 B
NO. 6 B  NO. 5 B
NO. 8 B  NO. 7
INSO
A  2089749
FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING
(SHEET 1 OF 3)
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### Page 55 (OCR)

BOEING SERVICE BULLETIN А3536
ALERT  ALERT
CAM LATCH
TYPICAL
C CAM LATCH AXIAL  CENTERLINE  LATCH PIN AXIAL  CENTERLINE
CAM LATCH (1  1 LATCH PIN
END VIEW
A-A
• 0.025
MAX
0.025-
MAX
0.025
MAX
0.025
MAX
CAM LATCH
2089750
FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING
(SHEET 2 OF 3)
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### Page 56

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) (d)--Cam LatchMeasure1
(a) (b) (d)-6-83137-2Latch PinMeasure
(c) (d)--Latch Pin FittingMeasure
(a) During rigging procedure the latch pin is not to contact the cam latch in any direction.
(b) Wrap a single layer of 0.002 inch thick shim stock around latch pins 1 and 8. Use thin tape to keep shim
in place. With latch pins 1 and 8 engaging their respective cam latches, and with latch pins 2 through 7
not contacting their respective cam latches in any direction, adjust if required, latch pin fittings 2 through
7 such that latch pins 2 through 7 axial centerlines and their respective cam latch axial centerlines are
within the tolerance shown.
(c) Adjust latch pin fittings by moving fitting on serrations and by adjusting shim thickness. On the two forward
and two aft cam latches the Latch Pin Fitting/Cam Latch gap is 0.14 +/- 0.01 inch. On the four center cam
latches the Latch Pin Fitting/Cam Latch gap is 0.08 +/- 0.01 inch. Make sure the maximum allowed shim
thickness of 0.20 inch is not exceeded.
(d) Refer to 707 AMM 52-11-0 as an accepted procedure for rigging.
FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING
(SHEET 3 OF 3)
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### Page 57 (OCR)

BOEING SERVICE BULLETIN А3536
ALERT  ALERT
1 :0.20 TO +0.10 INCH  -5.08 TO +2.54 mm)
-5.08 TO +2.54 mm)  1) -0.20 TO +0.20 INCH
-5.08 TO +5.08 mm)
MAIN CARGO DOOR
‚DOOR
SCALE
INBD
FUSELAGE
A-A  2089752
NOTE: THIS VIEW SHOWS A NEGATIVE FLUSHNESS
FIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT
(SHEET 1 OF 2)
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### Page 58

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)--Main Cargo DoorMeasure1
(a) Hold scale 90 degrees to door edge. Make sure the MCD lower edge and lower corner flushness are
within the tolerance shown.
(b) Refer to 707 AMM 52-11-0 as an accepted procedure for flushness measurement.
FIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT
(SHEET 2 OF 2)
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### Page 59

1. Prepare to Adjust the Latch Mechanisms (Appendix Figure A1.1)
WARNING: MAKE SURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE CARGO
DOOR PATH BEFORE YOU OPERATE THE CARGO DOOR CONTROL SWITCH. THE
CARGO DOOR CAN CONTINUE TO MOVE AFTER YOU RELEASE THE SWITCH. THIS
CAN CAUSE INJURIES TO PERSONNEL AND DAMAGE TO EQUIPMENT.
a. Electrically close the door to the "latched-and-locked" position.
b. Use tape to mark the approximate location of the cam latch head, locations 1 through 8, on the external
side of the door.
c. Using a tape measurer, measure the external cargo door flushness between the sill plate and the door
at cam latch heads 1 through 8 (Appendix Figure A3).
d. Record the flushness measurements at cam latch head locations 1 through 8 (Appendix Figure A4.1).
e. Open the main cargo door to approximately 1/4 of the fully open position.
f. Clean the lower sill area around the latch pins and latch pin fittings with a cotton cloth.
g. Clean the head and throat of the cam latches with a cotton cloth.
h. Remove the cross bolt and clip or the cross bolt and nut from the latch pin fitting at sill locations 2
through 7.
i. Remove the latch pins at sill fitting locations 2 through 7 from the latch pin fittings (Appendix Figure
A1.3).
j. Record the latch pin location to the mating latch pin fitting.
k. Clean the latch pin holes in the latch pin fittings.
l. Wrap a 0.002 in. (0.051 mm) shim fully around the latch pins at sill fitting locations 1 and 8, making a
full circle.
(1) Make sure that you do not overlap the shims.
(2) Use thin tape to hold the ends of the 0.002 in. (0.051 mm) shim.
(3) Turn the shim until the splice points to the inboard side of the latch pin.
m. Electrically close the door to the "latched-and-locked" position.
n. Make sure that the 0.002 in. (0.051 mm) shims are on the pins.
o. Record the external flushness values for cam latch head locations 1 through 8 (Appendix Figure A4.1).
APPENDIX A:  LATCH MECHANISM ADJUSTMENT TEST
(SHEET 1 OF 18)
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### Page 60

NOTE: Flushness values show if it is necessary to adjust fittings 1 and 8. You will not rig the door
with these flushness values.
NOTE: Have the same person measure the flushness as measured earlier in the task.
p. Do these steps for latch fittings 1 and 8 if the lower edge flushness values are more than the tolerances
(Appendix Figure A3).
(1) Remove latch fitting fillet seals.
(2) Remove the cap seals.
(3) Remove the leveling compound.
(4) Record the location of the latch pin fitting on the mating serrated plate.
(5) Measure shim thickness to make sure that the latch pin fitting 1 and 8 adjustments can move the
door into the necessary flushness (Appendix Figure A1.3).
NOTE: If you remove 0.10 in. (2.54 mm) of the shim thickness, the door will move approximately
0.07 in. (1.78 mm) in the inboard direction.
(6) Do these steps if the door is more than the flushness tolerance in this configuration:
(a) Remove only one of the setscrew lock wires.
(b) Loosen the setscrew to loosen the fitting.
(c) You may need to use a 1/4 inch 8 point socket.
(d) Remove the fitting.
(e) Record the location of the fasteners.
(f) Record the corresponding latch pin fitting location number on the serrated plate.
(g) Carefully clean the serrations and all mating surfaces. Be careful to not remove the recorded
location numbers and location marks.
(h) Adjust the latch pin shim thickness.
(i) If you move the latch pin fitting inboard, then increase the clearance between the stop pin and
the stop pad.
(j) Move the latch fitting up one serration if you removed more than 0.071 in. (1.803 mm) shim
thickness.
(k) Move the latch fitting down one serration if you added more than 0.071 in. (1.803 mm) shim
thickness.
APPENDIX A:  LATCH MECHANISM ADJUSTMENT TEST
(SHEET 2 OF 18)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 06, 2012
A3536
60 of 76
BOEING SERVICE BULLETIN A3536
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