Copy · SB 707-A3542--BOEING · 67 pages

© 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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Show pages 25–36

More DataHole DiaQtyIdentificationNameCode --25BACR15BB6D7CRIVET, UNIVERSAL HD L

(a)0.325-0.32811BACB30MY10K( )XBOLT, PROTRUDING HD M -0.325-0.32811BACC30AG10COLLAR ASSEMBLY

(a)0.325-0.3281BACB30NW10K14XBOLT, 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 accepted procedure.

FIGURE 1: CAM SUPPORT ASSEMBLY AT STA 487.10 AND 500 - REPLACEMENT (SHEET 12 OF 12) Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.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 37 of 67 BOEING SERVICE BULLETIN A3542

ALERTALERT

Page 38OCROpen in PDF

BOEING SERVICE BULLETIN А3542

ALERT ALERT D INBD 2459675 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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(SHEET 1 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3542 Work - See page 1 for details. 38 of 67

Page 39OCROpen in PDF

BOEING SERVICE BULLETIN A3542

ALERT ALERT 91U1518 STA 500 OR STA 540 STA 520

OR WEB STA 560 ASSEMBLY CAM SUPPORT 500/520 ONLY STA 16 LOCATIONS (4 17 (4 LOCATIONS) RADIUS FILLER 13 BRACKET 6 LOCATIONS (12 14 3 18 10 17

TENSION TIE CLIP 92969P6 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 2 OF 12) Original Issue: February 12, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING A3542 Work - See page 1 for details. 39 of 67

Page 40OCROpen in PDF

BOEING SERVICE BULLETIN А3542

ALERT ALERT STA 560 STA 600 OR 3€080UUD18 STA 540 OR CAM SUPPORT STA 580

ASSEMBLY DO 16 LOCATIONS (16 17) 10 LOCATIONS WEB STA 13) RADIUS FILLE 580/600 BRACKET / 14 LOCATIONS ONLY 00® 12 14) 6 LOCATIONS 117

TENSION TIE CLIP 10U118 (15 18

SHEAR WEB CAM AND BELLCRANK ASSEMBLY 2459680 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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. 40 of 67

Page 41OCROpen in PDF

BOEING SERVICE BULLETIN A3542

ALERT ALERT

CAM SUPPORT

ASSEMBLY STA 520 CAM SUPPORT ASSEMBLY STA 560 OR

SHEAR WEB **** 7 7 7 7% B-B TIE CLIP + STA 520 ONLY G STA 560 ONLY

SHEAR WEB

TENSION TIE CLIP A-A 2459686 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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. 41 of 67

Page 42OCROpen in PDF

BOEING SERVICE BULLETIN A3542

ALERT ALERT STA 540 OR STA 580

CAM SUPPORT

ASSEMBLY G- STA 540 ONLY

- STA 580 ONLY

SHEAR WEB

CAM SUPPORT

ASSEMBLY ALE

BRACKET

SHEAR WEB

TENSION

TENSION TIE CLIP TIE CLIP D-D C-C 2459687 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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. 42 of 67

Page 43OCROpen in PDF

BOEING SERVICE BULLETIN A3542

ALERT ALERT STA 520 STA 580 INBD

CAM SUPPORT

CAM SUPPORT ASSEMBLY

ASSEMBLY

SHEAR WEB

STA STA 540 520 E-E 2459702 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 6 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING A3542 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 67

Page 44OCROpen in PDF

BOEING SERVICE BULLETIN А3542

ALERT ALERT

CAM SUPPORT

CAM SUPPORT ASSEMBLY

ASSEMBLY

SHEAR WEB

STA STA 580 560 FWD F-F 2459800 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - REPLACEMENT (SHEET 7 OF 12) Original Issue: February 12, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished A3542 Work - See page 1 for details. 44 of 67

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 Keep cam support assembly at STA 540 or STA 580 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) -1-CAM AND BELL-

CRANK ASSEMBLY Install (Temporary) Pick up existing holes.

-69-23588U9CAM SUPPORT AS- SEMBLY Drill4 --BRACKET -1-CAM AND BELL-

CRANK ASSEMBLY Remove / Keep5 1-CAM SUPPORT AS- SEMBLY Remove (Kept) -169-23588U10CAM SUPPORT AS- SEMBLY Put / Hold (New)6 1-BRACKETPut / Hold (Kept) 1-CAM AND BELL-

CRANK ASSEMBLY Install (Temporary) FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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 45 of 67 BOEING SERVICE BULLETIN A3542

ALERTALERT

More DataQtyIdentificationNameTaskStep 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 -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

(a)-69-23588U9CAM SUPPORT AS- SEMBLY Drill (Kept)12 -69-23588U10CAM SUPPORT AS- SEMBLY --SHEAR WEB ----Clean/Deburr

(b)8-RADIUS FILLERMake13 FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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 46 of 67 BOEING SERVICE BULLETIN A3542

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More DataQtyIdentificationNameTaskStep 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

(c) (d)169-23588U9CAM SUPPORT AS- SEMBLY Install (Kept)18 169-23588U10CAM SUPPORT AS- SEMBLY -2-BRACKET 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 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) 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.

FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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 47 of 67 BOEING SERVICE BULLETIN A3542

ALERTALERT

More DataQtyIdentificationNameTaskStep

(b) 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.

(c) 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.

(d) 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.

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)0.325-0.32820BACB30MY10K( )XBOLT, PROTRUDING HD A -0.325-0.32820BACC30M10COLLAR

(a)0.2651-0.26618BACB30MY8K( )XBOLT, PROTRUDING HD B -0.2651-0.26618BACC30M8COLLAR

(a)0.2651-0.26614BACB30LM4-( )XBOLTC -0.2651-0.26614BACW10AW4ASWASHER, OVERSIZE -0.2651-0.26614BACN10JC4CDNUT,SELF-LOCKING

(a)0.2651-0.26614BACB30NW8K( )XBOLT, 100 DEG HEX DR D -0.2651-0.26614BACC30M8COLLAR FIGURE 2: CAM SUPPORT ASSEMBLY AT STA 520, 540, 560, 580 - 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 48 of 67 BOEING SERVICE BULLETIN A3542

ALERTALERT

Pages 49–60 of 67