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© 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.

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Page 25Open in PDF

2. RC - Do an Ultrasonic Inspection of the grease fitting lug area of affected main cargo door cam support assemblies for any crack in accordance with 707, 720 NDT Manual Part 4, 52-30-01.

NOTE: 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. CONDITION 1: NO CRACK FOUND

(1) 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 in accordance with 707, 720 NDT Manual Part 4, 52-30-01 at the repeat interval given in Paragraph 1.E., Compliance.

NOTE: 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.

b. CONDITION 2: ANY CRACK FOUND

(1) Do PART 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENT.

(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 in accordance with 707, 720 NDT Manual Part 4, 52-30-01 at the repeat interval given in Paragraph 1.E., Compliance.

NOTE: 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.

3. Do an operational test of the main cargo door and check all affected hydraulic tubing and hoses for leakage. Refer to 707 AMM 52-11-0 for an accepted procedure.

4. Put the airplane back to a serviceable condition.

PART 1: MAIN CARGO DOOR CAM SUPPORT ASSEMBLY REPLACEMENT

1. Replace the main cargo door cam support assembly pair at the affected locations as follows:

NOTE: Refer to APPENDIX B for additional access.

a. Replace the cam support assembly at stations 487.10 and 500 in accordance with FIGURE

1.

b. Replace the cam support assembly at stations 520 and 540 in accordance with FIGURE 2.

c. Replace the cam support assembly at stations 560 and 580 in accordance with FIGURE 2.

d. Replace the cam support assembly at stations 600 and 612.9 in accordance with FIGURE 3.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: February 12, 2016 A3542 25 of 67 BOEING SERVICE BULLETIN A3542

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Page 26OCROpen in PDF

BOEING SERVICE BULLETIN А3542

ALERT ALERT INBD 2458993 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 1 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3542 Work - See page 1 for details. 26 of 67

Page 27OCROpen in PDF

BOEING SERVICE BULLETIN А3542

ALERT ALERT STA

487.10

CAM SUPPORT ASSEMBLY 4U 16 LOCATIONS

SUPPORT ASSEMBLY 0001 D 14 15 18

BRACKET 6 LOCATIONS (12) 13 8 18 ® (4 LOCATIONS)

LA TENSION

TIE CLIP > PART PROFILE SHOWN IS REFERENCE ONLY 2459294 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 2 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING A3542 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 67

Page 28OCROpen in PDF

BOEING SERVICE BULLETIN А3542

ALERT ALERT STA 520 3€G80ULD18 WEB STA CAM SUPPORT 500

ASSEMBLY TU 16 LOCATIONS (16 17) 10 LOCATIONS

13) RADIUS FILLE / 14 LOCATIONS

BRACKET 1001 12 14) 6 LOCATIONS X17

TENSION TIE CLIP 19 1 118 19 11 14 15 18

SHEAR WEB CAM AND BELLCRANK ASSEMBLY 2459297 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 3 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3542 Work - See page 1 for details. 28 of 67

Page 29OCROpen in PDF

BOEING SERVICE BULLETIN A3542

ALERT ALERT

CAM SUPPORT

ASSEMBLY

CAM SUPPORT

ASSEMBLY STA

487.10

SHEAR WEB · ·*··* * * · TENSION

TIE CLIP B-B

- BRACKET

SHEAR WEB B

TENSION TIE CLIP A-A 2459400 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - 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. 29 of 67

Page 30OCROpen in PDF

BOEING SERVICE BULLETIN А3542

ALERT ALERT STA 500 CAM SUPPORT

ASSEMBLY AlES

SHEAR WEB

CAM SUPPORT AlE ASSEMBLY

BRACKET

SHEAR WEB

TENSION TIE CLIP C-C

TENSION TIE CLIP D-D 2459473 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 5 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3542 Work - See page 1 for details. 30 of 67

Page 31OCROpen in PDF

BOEING SERVICE BULLETIN A3542

ALERT ALERT

CAM SUPPORT

ASSEMBLY STA

487.10

CAM SUPPORT

ASSEMBLY STA STA 2459436 500 E-E 487.10 FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 6 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 67

Page 32Open in PDF

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 500 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 -169-23588U9CAM 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.

-69-23588U9CAM 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 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 7 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: February 12, 2016 A3542 32 of 67 BOEING SERVICE BULLETIN A3542

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Page 33Open in PDF

More DataQtyIdentificationNameTaskStep -169-23588U10CAM SUPPORT AS- SEMBLY Put / Hold (New)6 1-BRACKETPut / Hold (Kept) 1-CAM AND BELL-

CRANK ASSEMBLY Install (Temporary) Pick up existing holes.

-69-23588U10CAM 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 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 8 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: February 12, 2016 A3542 33 of 67 BOEING SERVICE BULLETIN A3542

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Page 34Open in PDF

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 locations 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 locations.

1-SHEAR WEB Install kept spacers.2-TENSION TIE CLIP Refer to CMM 52- 36-61 for an accepted procedure.

1-CAM AND BELL-

CRANK ASSEMBLY FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 9 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: February 12, 2016 A3542 34 of 67 BOEING SERVICE BULLETIN A3542

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Page 35Open in PDF

More DataQtyIdentificationNameTaskStep Fay and fillet seal with BMS 5-95 sealant. Refer to SOPM 20-50-19 for an accepted procedure.

1-WEBInstall (Kept)19 Refer to 707 AMM 52-11-0 for an accepted 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 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 10 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: February 12, 2016 A3542 35 of 67 BOEING SERVICE BULLETIN A3542

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Page 36Open in PDF

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)0.325-0.3281BACB30NW10K6XBOLT, 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)0.200-0.2035BACB30NX6K3XBOLT, PROTRUDING HD K

0.200-0.2035BACC30M6COLLAR FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 11 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.

Original Issue: February 12, 2016 A3542 36 of 67 BOEING SERVICE BULLETIN A3542

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Pages 37–48 of 67