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Page 13Open in PDF

Table 1: Main Cargo Door Cam Support Assembly - Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 1,790 flight cycles or 24 months after the original issue date of this service bulletin, 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 Do an Ultrasonic Inspection of the grease fitting lug area of affected main cargo door cam support assemblies for any crack.

(a) All airplanes 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. (a) CONDITION 1: NO

CRACK FOUND --Before further flight ACTION 1: Do PART 1:

MAIN CARGO DOOR

CAM SUPPORT ASSEM- BLY REPLACEMENT.

CONDITION 2: ANY

CRACK FOUND 4,000 flight cycles or 10 years, whichever occurs first --ACTION 2: 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. (a)

(a) 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.

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 This service bulletin and its approval were based on Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: February 12, 2016 A3542 13 of 67 BOEING SERVICE BULLETIN A3542

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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 tables below show an estimate of the task hours necessary to do this inspection for each airplane and to replace each pair of cam latch support fittings. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task hour data if necessary. The estimate does not include lost time. These are some examples of lost time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

Inspection Elapsed HoursTask HoursNumber of PersonsTask

1.501.501Preparation

2.502.501Inspect

1.501.501Restoration

5.505.50TOTAL FOR EACH AIRPLANE Replacement Elapsed HoursTask HoursNumber of PersonsTask 6122Open Access 16322FIGURE 1 16322FIGURE 2 16322FIGURE 3 8162Close Access 3060TOTAL FOR EACH CAM SUPPORT FIT-

TING PAIR H. Weight and Balance Changes None.

Original Issue: February 12, 2016 A3542 14 of 67 BOEING SERVICE BULLETIN A3542

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I. Electrical Load Data Not changed.

J. References

1. Existing Data:

a. Boeing Service Letter 707-SL-00-011

b. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-01, 20-50-19

c. 707 Aircraft Maintenance Manual (AMM) 52-11-0

d. 707 Corrosion Prevention Manual (CPM) 52-30-07

e. 707, 720 Non-Destructive Testing (NDT) Manual Part 4, 52-30-01

f. Component Maintenance Manual (CMM) 52-36-61

g. Boeing Service Bulletin 707A3387

2. Data Supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

None.

K. Publications Affected

1. Publications:

Chapter-SectionPublication PART 4, 52-30-01707 Non-Destructive Testing Manual

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin affects FCS. DTI requirements for the structure affected are contained in Paragraph 1.E., Compliance of this service bulletin.

L. Interchangeability and Intermixability of Parts Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

M. Software Accomplishment Summary Not affected.

Original Issue: February 12, 2016 A3542 15 of 67 BOEING SERVICE BULLETIN A3542

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Original Issue: February 12, 2016 A3542 16 of 67 BOEING SERVICE BULLETIN A3542

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BLANK PAGE

Page 17Open in PDF

2. MATERIAL INFORMATION A. Material - Price and Availability Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kit is subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

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 The Boeing PART Page

2. Fax to (206) 662-7145 REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION Unit Price as of the original issue date of this Service Bulletin (US Dollars) ROLT as of the original issue date of this Service Bulletin (Calendar Days) NameKit Number

TOP KIT - RETROFIT KIT FOR MAIN DECK

CARGO DOOR 65C38659-17 Operators are encouraged to complete the survey provided in APPENDIX C of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

B. Industry Support Information Boeing warranty remedies are not available for the inspection and repair procedures given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

NOTE: Up to four (4) top kits are necessary for each airplane based on inspection findings. Top kit is configured for the replacement of any single pair of cam support assemblies.

Original Issue: February 12, 2016 A3542 17 of 67 BOEING SERVICE BULLETIN A3542

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ALL Kit 65C38659 NotesExisting Part Number NameQtyNew Part Number -17

(a)-TOP KIT -

RETROFIT KIT

FOR MAIN DECK

CARGO DOOR -65C38659-17

(c)-CAM SUPPORT

ASSEMBLY 169-23588U10

(c)-CAM SUPPORT

ASSEMBLY 169-23588U9

(b)-bolt6BACB30LM3-4X

(b)-BOLT9BACB30LM3-6X

(b)-BOLT2BACB30LM3-8X

(b)-BOLT3BACB30LM4-4X

(b)-BOLT6BACB30LM4-6X

(b)-BOLT2BACB30LM4-7X

(b)-BOLT2BACB30LM4-8X

(b)-BOLT2BACB30LM4-9X

(b)-BOLT, PROTRUD- ING HD 4BACB30MY10K10X

(b)-BOLT, PROTRUD- ING HD 4BACB30MY10K11X

(b)-BOLT, PROTRUD- ING HD 2BACB30MY10K13X

(b)-BOLT, PROTRUD- ING HD 1BACB30MY10K14X

(b)-BOLT, PROTRUD- ING HD 2BACB30MY10K15X

(b)-BOLT, PROTRUD- ING HD 1BACB30MY10K16X

(b)-BOLT, PROTRUD- ING HD 1BACB30MY10K17X

(b)-BOLT, PROTRUD- ING HD 2BACB30MY10K18X

Original Issue: February 12, 2016 A3542 18 of 67 BOEING SERVICE BULLETIN A3542

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ALL Kit 65C38659 NotesExisting Part Number NameQtyNew Part Number -17

(b)-BOLT, PROTRUD- ING HD 3BACB30MY10K21X

(b)-BOLT, PROTRUD- ING HD 2BACB30MY10K22X

(b)-BOLT, PROTRUD- ING HD 2BACB30MY10K23X

(b)-BOLT, PROTRUD- ING HD 12BACB30MY10K5X

(b)-BOLT, PROTRUD- ING HD 4BACB30MY10K6X

(b)-BOLT, PROTRUD- ING HD 2BACB30MY10K7X

(b)-BOLT, PROTRUD- ING HD 4BACB30MY10K9X

(b)-BOLT, PROTRUD- ING HD 1BACB30MY12K10X

(b)-BOLT, PROTRUD- ING HD 4BACB30MY8K5X

(b)-BOLT, PROTRUD- ING HD 5BACB30MY8K7X

(b)-BOLT, 100 DEG HEX DR 1BACB30NW10K14X

(b)-BOLT, 100 DEG HEX DR 1BACB30NW10K15X

(b)-BOLT, 100 DEG HEX DR 1BACB30NW10K6X

(b)-BOLT, 100 DEG HEX DR 1BACB30NW10K7X

(b)-BOLT, 100 DEG HEX DR 2BACB30NW8K5X

(b)-BOLT, 100 DEG HEX DR 2BACB30NW8K7X

(b)-BOLT, PROTRUD- ING HD 5BACB30NX6K3X

Original Issue: February 12, 2016 A3542 19 of 67 BOEING SERVICE BULLETIN A3542

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ALL Kit 65C38659 NotesExisting Part Number NameQtyNew Part Number -17

(b)-BOLT, PROTRUD- ING HD 1BACB30NX6K5X

(b)-BOLT, PROTRUD- ING HD 1BACB30NX6K6X --COLLAR ASSEM- BLY 12BACC30AG10 --COLLAR20BACC30M10 --COLLAR1BACC30M12 --COLLAR7BACC30M6 --COLLAR13BACC30M8 --NUT16BACN10JC3CD --NUT,SELF-LOCK- ING 14BACN10JC4CD --RIVET, UNIVER- SAL HD 25BACR15BB6D7C --RIVET, 100 DEG4BACR15GF8D14 --WASHER, OVER- SIZE 16BACW10AW3AS --WASHER, OVER- SIZE 14BACW10AW4AS

(a) There are more parts than are necessary.

(b) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, substitute fasteners may be supplied in kits.

(c) To make installation easier, some Boeing parts are sent in an 'interim' configuration. Boeing will identify these interim configurations with a 'U', 'W' or 'Y' in place of the '-' (dash) in the part number. Interim parts are changed to the 'dash' configuration when installed as given in the Accomplishment Instructions of this service bulletin. Refer to Boeing Drawing 005W0900 "INTERIM PARTS - SPARES" and Boeing Service Letter 707- SL-00-011 for more information.

Original Issue: February 12, 2016 A3542 20 of 67 BOEING SERVICE BULLETIN A3542

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2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available.

NotesNameQTYPart Number / Specification Refer to FIGURE 1, FIG- URE 2, and FIGURE 3. Optional to make in one piece rather than 4. (b) RADIUS FILLER-2024-T3 ALCLAD, 2024-T4 ALCLAD, or 7075-T6 AL- CLAD

(a)SEALANT - PRESSURE AND ENVI-

RONMENTAL - CHROMATE TYPE -BMS 5-95

(a)COATING - CHEMICAL AND SOL-

VENT RESISTANT FINISH, CORRO-

SION INHIBITING PRIMER -BMS 10-11, TYPE I

(a)COATING - CHEMICAL AND SOL-

VENT RESISTANT FINISH - BAC 702 WHITE COLOR, GLOSS -BMS 10-11, TYPE II

(a)COATING - ORGANIC CORRO-

SION INHIBITING COMPOUND -BMS 3-23, TYPE II

(a)GREASE - AIRCRAFT GENERAL

PURPOSE -BMS 3-33

(a) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data.

(b) 0.75 Inch X 0.75 Inch X 0.125 Inch No special parts or materials are necessary to do the change in this service bulletin. But, parts and materials in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available.

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 None.

Original Issue: February 12, 2016 A3542 21 of 67 BOEING SERVICE BULLETIN A3542

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F. Special Tooling Necessary to do this Service Bulletin No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine operator tool supply to make sure all necessary tools are available.

Original Issue: February 12, 2016 A3542 22 of 67 BOEING SERVICE BULLETIN A3542

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3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE.

NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values:

— Values for structural fasteners are given in 707 Structural Repair Manual, Chapter 51.

— Values for airframe maintenance tasks are included in Chapter 20 of 707 Aircraft Maintenance Manual (AMM).

— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).

— Values for engine maintenance tasks are included in Chapter 70 of 707 Aircraft Maintenance Manual (AMM).

— Non-standard torque values for maintenance tasks are included in the applicable installation step.

4. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.

5. If the length of any fastener specified in this service bulletin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin.

6. 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.

Original Issue: February 12, 2016 A3542 23 of 67 BOEING SERVICE BULLETIN A3542

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7. Refer to APPENDIX A for the logic diagram. The logic diagram is provided as an aid only. Information contained in Paragraph 1.E., Compliance is the primary source for compliance times. Information in Paragraph 3.B., WORK INSTRUCTIONS is the primary source for tasks required for compliance.

8. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools.

9. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed.

10. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part.

11. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems.

12. Some Boeing parts are supplied in a temporary configuration. Those parts are identified with a 'U', 'W', or 'Y' in place of the '-' (dash) in the part number. It is permitted to install parts identified with a 'U', 'W', or 'Y' as an alternative to the '-' (dash) part number. Boeing Drawing 005W0900 contains more data.

13. Use of colors in Figures is based on guidance from the ATA e-Business Program (ATA) iSpec 2200.

14. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION numbers for that CONDITION number or OPTION number.

15. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance.

16. Some steps in the Work Instructions are labeled as Required for Compliance (RC).

If this service bulletin is mandated by an Airworthiness Directive (AD), then the steps labeled as RC, including sub-steps under an RC step and any figures identified in an RC step, must be done to comply with the AD. An Alternative Method of Compliance (AMOC) is required for any deviations to RC steps, including sub-steps and identified figures. Steps not labeled as RC may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC. This is provided that the RC steps, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition.

B. WORK INSTRUCTIONS

1. Open the main cargo door. Refer to 707 AMM 52-11-0 for an accepted procedure.

Original Issue: February 12, 2016 A3542 24 of 67 BOEING SERVICE BULLETIN A3542

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