# Boeing Service Bulletin A3542: No revision named, from page 49

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2016-9183; AD 2017-18-20 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Service Bulletin A3542](https://openairdocs.org/service-documents/boeing/a3542.md)
- Title as filed: SB 707-A3542--BOEING
- Pages: 67
- PDF: https://openairdocs.org/files/sha256/d0/40/d040bf682d1ed47cae6437e743ef159aedc0854037c7304498180d9bb75f395f
- Page: https://openairdocs.org/service-documents/boeing/a3542/file/d040bf682d1e

## 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 49

More DataHole DiaQtyIdentificationNameCode
--4BACR15GF8D14RIVET, 100 DEGE
(a) (b)0.2026-0.203616BACB30LM3-( )XBOLTF
(b)0.2026-0.203616BACW10AW3ASWASHER, OVERSIZE
(b)0.2026-0.203616BACN10JC3CDNUT
(a) (b)0.263-0.2661BACB30MY8K7XBOLT, PROTRUDING
HD
G
(b)0.263-0.2661BACC30M8COLLAR
(a)0.325-0.32812BACB30MY10K( )XBOLT, PROTRUDING
HD
H
(a)0.325-0.32812BACC30AG10COLLAR ASSEMBLY
Pick up existing hole in
the pressure door hinge
structure. Use the existing
fastener.
0.250-0.254---I
(a)0.200-0.2032BACB30NX6K( )XBOLT, PROTRUDING
HD
J
-0.200-0.2032BACC30M6COLLAR
(a)0.200-0.2035BACB30NX6K3XBOLT, PROTRUDING
HD
K
-0.200-0.2035BACC30M6COLLAR
--25BACR15BB6D7CRIVET, UNIVERSAL
HD
L
(a) Install wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted procedure.
(b) Touch up bolt head, washer/nut, or collar, as applicable, below door lower frame with BMS 10-11, Type
I primer and BMS 10-11 Type II enamel, color BAC 702 white gloss. Refer to SOPM 20-41-02 for an ac-
cepted procedure.
FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT
(SHEET 12 OF 12)
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A3542
49 of 67
BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 50 (OCR)

BOEING SERVICE BULLETIN А3542
ALERT  ALERT
INBD  2461473
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 1 OF 12)
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PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.  50 of 67

### Page 51 (OCR)

BOEING SERVICE BULLETIN А3542
ALERT  ALERT
STA
612.9
CAM SUPPORT ASSEMBLY
16 LOCATIONS A 1
SUPPORT ASSEMBLY
D000B
16 17 10 LOCATIONS
BRACKET
12 14 6 LOCATIONS
(4 LOCATIONS)  RADIUS FILLER 13
TENSION
TIE CLIP
> PART PROFILE SHOWN IS REFERENCE ONLY
2461477
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 2 OF 12)
Original Issue: February 12, 2016
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### Page 52 (OCR)

BOEING SERVICE BULLETIN А3542
ALERT  ALERT
8 0UU4 1518  STA
580
WEB
STA
600  CAM SUPPORT
ASSEMBLY
16 LOCATIONS (7 17)
(4 LOCATIONS)  RADIOS FILLER 13  BRACKET
6 LOCATIONS (12) 14  6 3 18
10 17  17
TENSION TIE CLIP
15 18
€031
191  15 18)
SHEAR WEB
ASSEMBLY  CAM AND BELLCRANK  2461478
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 3 OF 12)
Original Issue: February 12, 2016
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Work - See page 1 for details.  52 of 67

### Page 53 (OCR)

BOEING SERVICE BULLETIN A3542
ALERT  ALERT
STA
612.9  CAM SUPPORT
ASSEMBLY
ME
NIE
ALE
ME  SHEAR WEB
CAM SUPPORT
ASSEMBLY
ALE
B :
BRACKET
SHEAR WEB
TENSION TIE CLIP
A-A
TENSION
TIE CLIP  B-B  2461481
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 4 OF 12)
Original Issue: February 12, 2016
PROPRIETARY - Copyright © Unpublished  Export Controlled ECCN: 9E991 - BOEING  A3542
Work - See page 1 for details.  53 of 67

### Page 54 (OCR)

BOEING SERVICE BULLETIN А3542
ALERT  ALERT
CAM SUPPORT
ASSEMBLY
CAM SUPPORT
ASSEMBLY  STA
600
SHEAR WEB
7 7 7 7  TENSION
TIE CLIP
D-D
- BRACKET
SHEAR WEB
TENSION TIE CLIP
C-C  2461482
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 5 OF 12)
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### Page 55 (OCR)

BOEING SERVICE BULLETIN А3542
ALERT  ALERT
CAM SUPPORT
ASSEMBLY
STA
612.9  CAM SUPPORT
ASSEMBLY
•
CAM SUPPORT  CAM SUPPORT
ASSEMBLY  ASSEMBLY
SHEAR WEB
612.9  STA  E-E  STA  600  2461483
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 6 OF 12)
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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 each airplane.
More DataQtyIdentificationNameTaskStep
-1-WEBRemove / Keep1
1-CAM AND BELL-
CRANK ASSEMBLY
Keep spacers.2-TENSION TIE CLIP
-1-SHEAR WEB
2-BRACKET
1-SUPPORT ASSEMBLY
Keep cam support
assembly at STA
600 for use as an
aid during alignment
of new cam support
assembly.
2-CAM SUPPORT AS-
SEMBLY
Remove
Temporary install
using existing holes
to maintain original
position.
1-CAM SUPPORT AS-
SEMBLY
Install (Kept)2
-169-23588U10CAM SUPPORT AS-
SEMBLY
Put / Hold (New)3
1-BRACKETPut / Hold (Kept)
(a)1-SUPPORT ASSEMBLY
-1-CAM AND BELL-
CRANK ASSEMBLY
Install (Temporary)
Pick up existing
holes.
-69-23588U10CAM SUPPORT AS-
SEMBLY
Drill4
--BRACKET
Pick up existing
holes. (a)
--SUPPORT ASSEMBLY
-1-CAM AND BELL-
CRANK ASSEMBLY
Remove / Keep5
1-CAM SUPPORT AS-
SEMBLY
Remove (Kept)
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 7 OF 12)
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BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 57

More DataQtyIdentificationNameTaskStep
-169-23588U9CAM SUPPORT AS-
SEMBLY
Put / Hold (New)6
1-BRACKETPut / Hold (Kept)
1-CAM AND BELL-
CRANK ASSEMBLY
Install (Temporary)
Pick up existing
holes.
-69-23588U9CAM SUPPORT AS-
SEMBLY
Drill7
--BRACKET
-1-CAM AND BELL-
CRANK ASSEMBLY
Remove / Keep8
169-23588U9CAM SUPPORT AS-
SEMBLY
169-23588U10CAM SUPPORT AS-
SEMBLY
2-BRACKET
1-SUPPORT ASSEMBLY
-169-23588U9CAM SUPPORT AS-
SEMBLY
Install (Temporary)9
169-23588U10CAM SUPPORT AS-
SEMBLY
1-SHEAR WEB
Install kept spacers.2-TENSION TIE CLIP
Pick up existing
holes in shear web
and tension tie clip.
-69-23588U9CAM SUPPORT AS-
SEMBLY
Drill (Kept)10
-69-23588U10CAM SUPPORT AS-
SEMBLY
--SHEAR WEB
--TENSION TIE CLIP
-169-23588U9CAM SUPPORT AS-
SEMBLY
Remove / Keep11
169-23588U10CAM SUPPORT AS-
SEMBLY
1-SHEAR WEB
Keep spacers.2-TENSION TIE CLIP
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 8 OF 12)
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BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 58

More DataQtyIdentificationNameTaskStep
(b)-69-23588U9CAM SUPPORT AS-
SEMBLY
Drill (Kept)12
-69-23588U10CAM SUPPORT AS-
SEMBLY
--SHEAR WEB
----Clean/Deburr
(c)8-RADIUS FILLERMake13
Bench work. Install
radius fillers at 3 lo-
cations on each cam
support assembly.
169-23588U9CAM SUPPORT AS-
SEMBLY
Assemble14
169-23588U10CAM SUPPORT AS-
SEMBLY
1-SHEAR WEB
Assembled cam
support assemblies
and shear web.
169-23588U9CAM SUPPORT AS-
SEMBLY
Put / Hold15
69-23588U10CAM SUPPORT AS-
SEMBLY
1-SHEAR WEB
Install kept spacers.2-TENSION TIE CLIP
---SHEAR WEBDrill16
----Clean/Deburr17
(d) (e)169-23588U9CAM SUPPORT AS-
SEMBLY
Install (Kept)18
169-23588U10CAM SUPPORT AS-
SEMBLY
-2-BRACKET
1-SUPPORT ASSEMBLY
Install radius fillers
at remaining loca-
tions.
1-SHEAR WEB
Install kept spacers.2-TENSION TIE CLIP
Refer to CMM 52-
36-61 for an accept-
ed procedure.
1-CAM AND BELL-
CRANK ASSEMBLY
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 9 OF 12)
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ALERTALERT

### Page 59

More DataQtyIdentificationNameTaskStep
Fay and fillet seal
with BMS 5-95
sealant. Refer to
SOPM 20-50-19 for
an accepted proce-
dure.
1-WEBInstall (Kept)19
Refer to 707 AMM
52-11-0 for an ac-
cepted procedure.
-BMS 3-33GREASEApply20
(a) The door hook mechanism can be used as an aid to position the support assembly. Additional put/hold
and drilling tasks may be necessary for the support assembly and are as required.
(b) Bench work. Temporary assemble through holes common to the tension tie clip. Maintain the main cargo
door frame-to-frame mounting surface distance between the cam support assemblies during drilling.
(c) Make from 2024-T3 alclad, 2024-T4 alclad, or 7075-T6 alclad aluminum. Approximately 0.75 inch square
by 0.125 inch thick. Optional to make in one piece rather than 4. Radius bottom of filler to fit curvature of
fitting (0.010 inch maximum gap prior to fastener installation. Apply chemical conversion coating Type 1
or Type 2, Class A or C. Refer to SOPM 20-43-03 as an accepted procedure. Apply two coats of BMS
10-11, Type I primer. Refer to SOPM 20-41-02 for an accepted procedure.
(d) Apply one layer of BMS 10-11, Type II enamel, color BAC 702 white gloss below door lower frame, except
in cam latch bores, prior to installation of cam and bellcrank assembly. Refer to SOPM 20-41-02 for an
accepted procedure..
(e) Apply BMS 3-23, Type II corrosion inhibiting compound above and below door lower frame, except in
cam latch bores, prior to installation of cam and bellcrank assembly. Refer to 707 CPM 52-30-07 and
SOPM 20-41-05 for an accepted procedure.
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 10 OF 12)
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BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 60

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.
A number in the lower right corner gives the grip length of the fastener. The QTY numbers shown below are the
number of fasteners necessary for this figure.
More DataHole DiaQtyIdentificationNameCode
(a)0.325-0.32818BACB30MY10K( )XBOLT, PROTRUDING
HD
A
-0.325-0.32818BACC30M10COLLAR
(a)0.325-0.3281BACB30NW10K7XBOLT, 100 DEG HEX
DR
B
-0.325-0.3281BACC30M10COLLAR
(a)0.388-0.3911BACB30MY12K10XBOLT, PROTRUDING
HD
C
-0.388-0.3911BACC30M12COLLAR
(a)0.2651-0.26618BACB30MY8K( )XBOLT, PROTRUDING
HD
D
-0.2651-0.26618BACC30M8COLLAR
(a)0.2651-0.26614BACB30LM4-( )XBOLTE
-0.2651-0.26614BACW10AW4ASWASHER, OVERSIZE
-0.2651-0.26614BACN10JC4CDNUT,SELF-LOCKING
(a)0.2651-0.26614BACB30NW8K( )XBOLT, 100 DEG HEX
DR
F
-0.2651-0.26614BACC30M8COLLAR
--4BACR15GF8D14RIVET, 100 DEGG
(a) (b)0.2651-0.266110BACB30LM4-( )XBOLTH
(b)0.2651-0.266110BACW10AW4ASWASHER, OVERSIZE
(b)0.2651-0.266110BACN10JC4CDNUT,SELF-LOCKING
(a) (b)0.263-0.2661BACB30MY8K7XBOLT, PROTRUDING
HD
I
(b)0.263-0.2661BACC30M8COLLAR
(a)0.200-0.2032BACB30NX6K( )XBOLT, PROTRUDING
HD
J
-0.200-0.2032BACC30M6COLLAR
(a)0.200-0.2035BACB30NX6K4XBOLT, PROTRUDING
HD
K
-0.200-0.2035BACC30M6COLLAR
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 11 OF 12)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
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BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 61

More DataHole DiaQtyIdentificationNameCode
--25BACR15BB6D7CRIVET, UNIVERSAL
HD
L
(a)0.325-0.32811BACB30MY10K( )XBOLT, PROTRUDING
HD
M
-0.325-0.32811BACC30AG10COLLAR ASSEMBLY
(a)0.325-0.3281BACB30NW10K15XBOLT, 100 DEG HEX
DR
N
-0.325-0.3281BACC30AG10COLLAR ASSEMBLY
Pick up existing hole in
the pressure door hinge
structure. Use the existing
fastener.
0.250-0.254---O
(a) Install wet with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted procedure.
(b) Touch up bolt head, washer/nut, or collar, as applicable, below door lower frame with BMS 10-11, Type
I primer and BMS 10-11 Type II enamel, color BAC 702 white gloss. Refer to SOPM 20-41-02 for an ac-
cepted procedure.
FIGURE 3: CAM SUPPORT ASSEMBLY AT STA 600 AND 612.9 - REPLACEMENT
(SHEET 12 OF 12)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: February 12, 2016
A3542
61 of 67
BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 62

Logic diagrams are provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary
source for compliance times. Information contained in Paragraph 3.B., Work Instructions is the primary source
for tasks required for compliance.
1. The table below gives the description for the parts and conditions called out in the logic diagrams.
DescriptionTitle
MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENTPART 1
NO CRACK FOUNDCONDITION 1
ANY CRACK FOUNDCONDITION 2
2. The table below gives the description for the flag notes called out in the logic diagram.
DescriptionFlag Note Letter
69-23588-5 and 69-23588-6 are affected part numbers. 69-23588-9 and 69-
23588-10 are also affected part numbers, if installed in accordance with PART
1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENT.
(a)
APPENDIX A:  LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: MAIN CARGO DOOR
CAM SUPPORT ASSEMBLY - INSPECTION
(SHEET 1 OF 2)
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BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 63 (OCR)

BOEING SERVICE BULLETIN A3542
ALERT  ALERT
WHICHEVER OCCURS LATER
BEFORE 18,000 TOTAL FLIGHT CYCLES OR
WITHIN 10 YEARS AFTER INSTALLATION
OF CAM SUPPORT ASSEMBLY PART
NUMBERS 69-23588-5 AND 69-23588-6 IN
ACCORDANCE WITH SERVICE BULLETIN
707A3387, WHICHEVER OCCURS FIRST
WITHIN 1,790 FLIGHT CYCLES OR 24
MONTHS AFTER THE ORIGINAL ISSUE
DATE OF THIS SERVICE BULLETIN,
WHICHEVER OCCURS LATER
DO AN ULTRASONIC INSPECTION OF THE GREASE
FITTING LUG AREA OF AFFECTED MAIN CARGO
DOOR CAM SUPPORT ASSEMBLIES FOR ANY CRACK
(a)
CONDITION 1
NOT TO EXCEED 4,000
FLIGHT CYCLES OR 10
YEARS, WHICHEVER
OCCURS FIRST
REPEAT THE ULTRASONIC INSPECTION
OF THE GREASE FITTING LUG AREA OF
THE MAIN CARGO DOOR CAM SUPPORT
ASSEMBLY AT ALL LOCATIONS WHERE
AN AFFECTED PART NUMBER IS
INSTALLED FOR ANY CRACK
CONDITION 2
BEFORE FURTHER FLIGHT
DO PART 1: MAIN CARGO
DOOR CAM SUPPORT
ASSEMBLY REPLACEMENT
NOT TO EXCEED 4,000 FLIGHT
CYCLES OR 10 YEARS,
WHICHEVER OCCURS FIRST
REPEAT THE ULTRASONIC INSPECTION OF THE
GREASE FITTING LUG AREA OF THE MAIN
CARGO DOOR CAM SUPPORT ASSEMBLY AT
ALL LOCATIONS WHERE AN AFFECTED PART
NUMBER IS INSTALLED FOR ANY CRACK
APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: MAIN CARGO DOOR
CAM SUPPORT ASSEMBLY - INSPECTION
(SHEET 2 OF 2)
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Export Controlled ECCN: 9E991 - BOEING  A3542
PROPRIETARY - Copyright © Unpublished
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### Page 64 (OCR)

BOEING SERVICE BULLETIN A3542
ALERT  ALERT
→ D
MAIN CARGO
DOOR LINING
PANELS
B
FORWARD CAM
ACTUATOR 2
AFT CAM
ACTUATOR  A ACTUATOR  LATCH
NO. 1 D
PRESSURE
DOOR
A LATCH  (2 LOCATIONS)
¡ ACTUATOR
NO. 2 D
PLATO
• ACTUATO  TEWD
NO. 31
I LATO
• ACTUATO
NO.4
INBD
2462008
APPENDIX B: ADDITIONAL ACCESS
(SHEET 1 OF 3)
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### Page 65

APPENDIX B:  ADDITIONAL ACCESS
(SHEET 2 OF 3)
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BOEING SERVICE BULLETIN A3542
ALERTALERT

### Page 66 (OCR)

BOEING SERVICE BULLETIN A3542
ALERT  ALERT
CAM
ACTUATOR •
CAM
ACTUATOR
c
LOWER
ACTUATOR
ATTACH
AFT CAM ACTUAT  I SHOWN,
FWD CAM ACTUATOR  OPPOSITE
REFER TO 707 AMM 52-11-11 FOR AN ACCEPTED REMOVAL AND
INSTALLATION PROCEDURE
REFER TO 707 AMM 52-11-21 FOR AN ACCEPTED REMOVAL AND
INSTALLATION PROCEDURE
REFER TO CMM 52-36-61 FOR AN ACCEPTED REMOVAL AND
INSTALLATION PROCEDURE
APPENDIX B: ADDITIONAL ACCESS
(SHEET 3 OF 3)
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### Page 67 (OCR)

BOEING SERVICE BULLETIN A3542
ALERT  ALERT
Boeing Part Demand Intent
After review of this service bulletin (SB), Boeing asks that the primary engineer fill out this survey to
elp Boeing predict the quantity and timing of the Boeing supplied kits
Airline:
Contact Name:
Date:
Contact E-mail:
• Yes  • No Have/will you recommend to your airline to accomplish this SB?
• Yes  • No Would issuance of an Airworthiness Directive change this decision?
When would you likely be starting this SB incorporation? Month/ Year
How many airplanes per month do you plan to accomplish? Airplane/Month
How many total airplanes do you plan to complete? Total Airplanes
For inspection related SBs, are you planning to replace on condition, or a fleet campaign to replace or
all airplanes regardless of condition:
- On Condition  _ Campaign
If you are not incorporating this SB at this time will you please help us understand the reason(s) why?
Your input will help us provide better customer support.
• Cost Prohibitive  Continue Inspections  • Other
Operator Comments:
Within 45 days of the SB issue, or as soon after as possible, please scan this form and send to:
sbsolutions@boeing.com
Disclalmer: The data provided in this survey will be used for planning purposes only and does not
constitute a commitment on any part of the airlines to purchase the parts in question, nor does it constitute
a commitment on the part of Boeing to deliver the parts in question. This survey is a projection to help
Boeing forecast demand levels and timing to better support the customers schedule.
2406495
APPENDIX C: PART DEMAND INTENT
(SHEET 1 OF 1)
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