Number: 

Date: 

Revision 2· 

ATA System: 

727-52.0142 

July 26, 1990 

April15, 1993 

5234 

Commercial 

Airplane 

Group 

727 

Service Bulletin 

Revision Transmittal Sheet 

SUBJECT: DOORS- MAIN CARGO DOOR- LATCH CAM REPLACEMENT AND PRESSURE RELIEF 

DOOR HINGE FITTING REPLACEMENT 

This revision includes all pages or the service bulletin. 

COMPLIANCE INFORMATION RELATED TO THIS REVISION 

Federal Aviation Administration (FAA) Alrwonhlness DlrectJVe 91-22-()4, Amendment 39-8064, is related to 

thiS service bulletin. 

No more wor1< Is necessary on a1rplanes changed by the lmtial release or Revision 1 of this service bulletin. 

SUMMARY 

This revision adds instructions to trim the hinge filling If there is interference between the cam and the hinge 

filling when the door is in the closed posltlon. Optional fasteners are added for the Installation of the hinge 

fitting. This revision also defines the maximum allowable wear limits for the latch cams. Circle note 10 of 

Figure 3 Is revised. 

Paragraph I.A.. Effectivity, shows changes of airplane operators. Each operator should examine the 

Effectivity paragraph for changes. 

Vertical lines are put on the left edge of each page, except In Paragraph lA. Effectlv•ty, to show the location 

of Important changes. 

Pages With a revision number and date, but no verllcal lines have no Important changes 

REVISION HISTORY 

lnllial Release: 

Revision 1 

Revision 2· 

July 26, 1990 

June 4, 1992 

April15, 1993 

BOEINC COMMERCllll. AIRPlANE GROUP P 0 BOX3701 SI:ATTLE. WASHINGTON 96124•2207 
, 
BDIIND 

Number: 

Date 

Revision 2: 

AT A System: 

727-5.2-0142 

July 26, 1990 

April15. 1993 

5234 

Commercial 

Airplane 

Group 

727 

Service Bulletin 

Summary 

SUBJECT: DOORS· MAIN CARGO DOOR· LATCH CAM REPLACEMENT AND PRESSURE RELIEF 

DOOR HINGE FITIING REPLACEMENT 

BACKGROUND 

The main cargo doors on the 727 Cargo and 

Freighter airplanes are almost lhe same as those 

on the 757 Package Freighter airplane. When the 

757 Package Freighter was designed, better latch 

cams and better hinge fittings for the pressure relief 

doors were designed for the main cargo door. 

Boemg has received several reports of wear of the 

lock stop part of hinge fittings on the pressure relief 

doors on 707 and 727 Cargo and Freighter 

airplanes. Boeing has also received reports of 

wear of lhe latch cams on the main cargo doors on 

707 and 727 Cargo and Freighter airplanes. Wear 

of the lock stop part of the hinge fitUngs and of lhe 

latch cams is thought to be caused by Incorrect 

operallon sequence of the hydraulic system of the 

main cargo door. 

This service bulletin shows how to Install the better 

latch cams and hinge fittings on main cargo doors. 

lnslallalion of the better parts Will extend the service 

life of the door latch system. 

Contmued operation with installed latch cams and 

hinge fillings that are wom beyond the lim11s g1ven 

1n this servoce bulletm is not satisfactory Persons 

cannot make sure that the main cargo door Is 

correctly latched and locked under all possible 

operallonal conditions if the hinge fitllngs or the 

latch cams are worn beyond the limits given In this 

service bullelln. 

ACTION 

At the next •c• check after receipt of this service 

bulletin, not to exceed 3000 night-cycles, do a 

v1sual Inspection of the mating surfaces on the 

hinge fil1ings and the latch cams. If the hinge 

fillings are not worn, or ere worn Within the limits 

given tn this service bulletin. either lnslall new 

h1nge fil1ings and latch cams, or do the visual 

Inspection agam at each ·5c· check, or 8000 

flight-hours, whichever occurs sooner. If the hinge 

fittings are wom beyond the limits given In this 

service bulletin, Install new hinge fittings and latch 

cams. If lhe latch cams ere worn or damaged, 

Install new hinge fittlngs and latch cams. Return to 

the normal inspeclion Interval after the new hinge 

fittings and latch cams are Installed as shown In this 

service bulle6n. 

Federal Aviation Administration {FAA) 

Airworthiness Directive 91-22-04. Amendment 

39-8064, is related to this service bulletin. 

EFFECTIVITY 

AII727- 100C and 727-200F senes airplanes 

MANPOWER 

Total Man-hours • 34 for each airplane 

Elapsed Time· 17 Hours 

MATERIAL INFORMATION 

Boeing Supplied Kll 

Refer to Paragraph I.F • Mat8rlal • Pnce and 

Availability. 

80£1NO COM~ERCIAL AIRPlANE GROUP P 0 eo~ 3707 SEATTLE. WI\SHINGTON 98124-2207 Summary Page 1 of 2 
BOEING SERVICE BULLETIN 727-52-0142 

&:? FIIO 

~ lNBO 

- PRESSURE 

REll E F 

DOOR 

rsy...__ 0 / 

ON REPLACE EACH PRES TH~ HINGE F lTTlNGS 

(2 PLACES) SURE RELIEF DOOR 

Jul26190 

REV .. 2· Ap r15193 

&:? F\10 

~ l NBD 

REPLACE CAMS ANDT~~ LATCH 

(4 PLACES) E BELLCRANK 

Summary p age 2 or 2 
BDII.IVII 

Number: 727-52..()142 

Date: July 26. 1990 

Revision 2: April15, 1993 

ATA System: 5234 

Commercial 

Airplane 

Group 

727 

Service Bulletin 

SUBJECT: DOORS- MAIN CARGO DOOR- LATCH CAM REPLACEMENT AND PRESSURE RELIEF 

DOOR HINGE FITTING REPLACEMENT 

I. PLANNING INFORMATION 

A. Effectivity 

1. Airplanes 

Refer to Service Bullelln Index Document D6-9825, Part 3 for Airplane Variable Number, Une 

Number, and Serial Number data. 

This service bulletin is for only these airplanes: 

IDENTIFICATION BY CUSTOMER. CUSTOMER CODE. GROUP AND VARIABLE NUMBER 

AERO PERU (PER) 

E5278 

ALASKA AIRLINES (ASA) 

E5058 E5142 

AMERICAN INTERNATIONAL AIRWAYS, INC. (CKF) 

E5050 

AMERIJET INTERNATIONAL. INC. (AMJ) 

E5161 E5403 

ARIANA AFGAN AIRLINES CO., LTD (AFG) 

E5410 E5424 

AVIANCA (A VI) 

E5451 E5453 

BELGIAN AIR FORCE (BLG) 

E5351-E5352 

BRADLEY AIR SERVICES (BRS) 

E5112 E5141 E5482 

CHINESE AIR FORCE (CAF) 

E5409 E5435 

CONTINENTAL AIRLINES. INC. (CAL) 

E5201 

Jul26190 

REV. 2: Apr 15193 

727-52-0142 

Page 1 of 33 
CORSAIR (CRA) 

E5114 

BOEING SERVICE BULLETIN 727-52-0142 

DHL CORPORATION/WORLDWIDE COURIER EXP. (DHL) 

E5046-E5047 E5273-E5274 E5281 E5382 E5402 

DIGEX AERO CARGO (DGX) 

E5481 

DOMINICANA AIRLINES (DOM) 

E5404 

ECHO BAY MINES (EKO) 

E5418 

EVERGREEN INTERNATIONAL AIRLINES (EVR) 

E5104·E5105 E5108 E5277 E5426 

FAMCO AVIATION AND MARITIME SERVICES LTD (FAM) 

E5353 

FEDERAL AVIATION ADMINISTRATION (FAA) 

E5241 

FEDERAL EXPRESS (FED) 

E5048-E5049 E5052·E5054 E5056-E5057 E5059·E5063 E5067 

E5163-E5164 E5221-E5224 E5226-E5240 E5242 E5408 

E5454 QL501-QL515 

ITAPEMIRIM TRANSPORTES AEREOS S.A. (ITP) 

E5406 

KELOWNA FLIGHTCRAFT AIR CHARTER L TO. (KEL) 

E5001 E5428 

LLOYD AERO BOLIVIANO (LAB) 

E5421 

NATIONAL AIRLINES LTD (NAN) 

E5501 

NOMADS. INC. (NOM) 

E5279 

REEVE ALEUTIAN AIRWAYS. INC. (RW) 

E5035 E5040 

ROYAL NEPAL AIRLINES (RNA) 

E5419 

ROYAL NEW ZEALAND AIR FORCE (RNZ) 

E5065 E5068 

RYAN INTERNATIONAL AIRLINES (RYN) 

E5101-E5102 

ES420 

E5003 E5007-E5011 E5031-E5032 E5039 

E541 1 E5413 E5415 E5433 

E5041-ES042 ES381 

E5483 E5502 

Jul26/90 

REV 2: Apr 15/93 

727-52-0142 

2 
BOEING SERVICE BULLETIN 727-52-0142 

TAESA (TES) 

E5455 

UNITED PARCEL SERVICE (UPS) 

E5002 E5004-E5006 E5033-E5034 

E5051 E5106-E5107 E5109-E5111 

E5225 E5243-E5245 E5251-E5252 

E5301-E5306 E5401 E5405 

E5429 

VARIG AIRLINES (VAR) 

E5272 E5407 E5412 

IDENTIFICATION BY VARIABLE NUMBER 

E5001-E5011 E5031-E5068 E5101-E5116 

E5221-E5245 E5251-E5252 E5271-E5281 

E5401-E5424 E5426-E5429 E5433 

E5501-E5502 QL501·QL515 

2. Spares 

E5036 

E5113 

E5271 

E5417 

E5141-E5143 

E5301-E5306 

E5435 

E5038 

E5115-E5116 

E5275-E5276 

E5422-E5423 

E5161-E5164 

E5351-E5353 

E5451·E5455 

E5043-E5045 

E5162 

E5280 

E5427 

E5201-E5203 

E5381-E5382 

E5481-E5483 

Examine your spares supply for the parts identified in Paragraph II.D., Existing Parts Accountability. 

If any parts are found, refer to Paragraph II.D., Existing Parts Accountability, for the recommended 

use. 

Jul26/90 

REV. 2: Apr 15/93 

727-52-0142 

3 
BOEING SERVICE BULLETIN 727-52-0142 

B. Reason 

The main cargo doors on the 727 Cargo and Freighter airplanes are almost the same as those on the 

757 Package Freighter airplane. When the 757 Package Freighter was designed, better latch cams, 

and better hinge fitllngs for the pressure relief doors were designed for the main cargo door. The new 

latch cams and hinge fiUings for the 757 Package Freighter were designed to provide better resistance 

to wear. 

This service bulletin shows how to install the better latch cams and hinge fiUings on the main cargo 

doors on 727 Cargo and Freighter airplanes. Installation of the better parts on the main cargo doors will 

extend the service life of the door latch system. 

Boeing has received several reports of wear of the lOCk stop part of hinge fitUngs on the pressure relief 

doors on 707 and 727 Cargo and Freighter airplanes. Boeing has also received reports of wear of the 

latch cams on the main cargo doors on 707 and 727 Cargo and Freighter airplanes. Wear of the lock 

stop part of the hinge fittings and of the latch cams Is thought to be caused by Incorrect operation 

sequence of the hydraulic system of the main cargo door. Incorrect operation sequence of the 

hydraulic system of the main cargo door can occur In service due to wear of components of the door's 

hydraulic system, or due to a hydraulic system that is not adjusted correctly. 

Continued operation with Installed latch cams and hinge fittings that are wom beyond the limits given In 

this service bulletin Is not satisfactory. Persons cannot make sure that the main cargo door Is correctly 

locked and latched under all possible operational condillons if the hinge frttings or the latch cams are 

wom beyond the limits given In this service bulletin. 

Revision 1 was Issued to include a new top kil that supersedes the old top kit. The new kit Includes two 

latch cams and a bellcrank for each station. The latch cams and bellcrank come as a matched set with 

holes drilled in line through the mating parts. This revision also adds instructions to trim the shear web 

at the forward and all latch cams. New Instructions on how to locate the pressure door hinge fittings 

are added. 

Revision 2 adds Instructions to trim the hinge fitting If there Is interference between the cam and the 

hinge fitting when the door is In the closed position. Optional fasteners are added for the installation of 

the hinge fitting. This revision also defines the maximum allowable wear limits for lhe latch cams. 

Circle note 10 or Figure 3 is revised. 

Jul26/90 

REV. 2: Apr 15/93 

727-52-0142 

4 
BOEING SERVICE BULLETIN 727-52..()142 

C. Description 

At lhe next ·c· check after receipt of this service bullebn, not to exceed 3000 ftoght-cyctes, do a visual 

Inspection or the mating surfaces of the hinge filtlngs (on the pressure relief doors) and the latch cams. 

lr the hinge filtlngs are not worn, Of are worn within the limits given in this service bulletin. either Install 

the new hinge fittings and latch cams as shown in this service bulletin, or do the visual Inspection again 

at each 'SC' check. or 8000 night-hours. whichever occurs sooner. tr the hinge finfngs are worn beyond 

the limfls given in this service bullelln, Install the new hinge finings and latch cams as shown in this 

service bulletin. rr the latch cams are worn or damaged, Install the new hinge fillings and latch cams as 

shown In this service bullelln. Arter the new hinge fillings and latch cams are installed. return to the 

normal Inspection Interval. 

lr It Is necessary to Install the new hinge fillings and latch cams. remove the lining and the insulation 

from the lower part of the main cargo door. Remove and discard the four pairs of latch cams along with 

their matched bellcranks. Install new latch cams and their matched bellcranks on the main cargo door, 

along with new latched-and-locked Indicators Remove the honge fittings from the pressure relief doors 

on the main cargo doOf and Install new hinge fittings on lhe pressure relief doors. Do a lest of the main 

cargo doOf to make sure lhatlhe door operetes. latches. and locks correctly. Do a lest of the control 

system for lhe door to make sure il operates correctly. Do a test of the wamong system for the main 

cargo dOOf to make sure it operates correcUy Install the lining and the insulation on lhe Inside of the 

cargo door and return the airplane to service 

Federal Aviation Administration (FAA) Airworthiness Directive 91-22·04, Amendment 39-8064, Is 

related lo this service bulletin. 

NOTES: 

1. If the main cargo door was deactivated as shown In Service Bulletin 727-29-0053 "Main 

Cargo Door Deacllvallon/Reacllvallon System Installation". and no allempt has been made 

to open the cargo door after it was deactivated, then the Inspection shown in this service 

bulletin can be Ignored 

2. If the main cargo door was deactivated as shown In Service Bulleton 727-29..0053 "Main 

Cargo Door Deactlvation/ReacttVatoon System Installation" then lhe changes shown In this 

service bulletin can be Ignored 

3. Time wtll be saved if the changes shown In this service bulletin are done at the same bme as 

the changes shown In Servoce Bulleton 727-52A0124 "Main Cargo Door Cam Support Fitting 

Inspection and Replacement• 

D. Approval 

This service bulletin was examined by the Federal Aviation Administration (FAA). The repairs and 

changes specified In this service bulletin comply with the applicable Federal Aviation Regulations (FAR) 

and are FAA approved 

The FAA has examined the lnspecllon and replacement procedures specified In Revision 2 to Service 

Bulletin 727-52-()142, "DOORS - MAIN CARGO DOOR - LATCH CAM REPLACEMENT AND 

PRESSURE REUEF DOOR HINGE FITIING REPLACEMENT". The FAA has approved the Inspection 

and replacement procedures on Revisoon 2 of Service Bullebn 727-52·0142 as an allemallve to those 

specofaed in Airworthiness Dorecttve (AD) 91-22-04 Amendmenl39-a064 

Jul26/90 

REV 2: Apr 15193 

727-52-0142 

5 
BOEING SERVICE BULLETIN 727-52-0142 

E. Manpower 

Approximately 34 man-hours are necessary to do this change on one airplane • 

The data below shows an estimate of the man-hOurs necessary lo do this change for each airplane. 

This estimate is for direct labor only, done by an experienced crew. Adjust lhe estimate with operator 

man·hour data If necessary. The estimate does not include lost time. These are some examples or lost 

time: Time to adjust to the workplace, Time to schedule the work, Time to examine the work, Tlme to 

cure the materials. Time to make the parts, Time lo find the tools 

Number of Elapsed 

Task Persons Man-Hours Time (Hours) 

Open Access 2 2 1 

Change 2 26 13 

Close Access 2 2 1 

Test 2 4 2 

TOTAL FOR AIRPLANE 34 17 

F. Material - Price and Availability 

Boeing can supply the kit shown in Paragraph II.A., Parts Necessary For Each Airplane, as shown 

below. Kit availability is shown in lhe Reorder Lead Time (ROL T). ROL T is calculated from the date 

Boeing gets lhe purchase order. 

Kit Number 

65-93535-1 (a) 

65-93535-9 

Name 

Top Kit 

Top Kit 

ROLT 

(weeks) 

51 

Unit Price thru 

Oct 3, 1993 

$ 15,326.00 

(a) Top Kit 65-93535-1 Is held from more sales. Top Kit 65-93535-9 supersedes old Top Kit. 

The kits are subject to the tenns and conditions or Boeing's standard purchase order acknowledgment. 

After the Unit Price date. new price and ROL T data Is applicable. Prices are in United States Dollars. 

Terms: Net 30 days. 

Send purchase orders and letters about the supply data to the Director of Spares and refer to this 

service bulletin number. 

G. Special Tools ·Price and Availability 

None 

H. Weight and Balance 

None 

Jul26/90 

REV. 2. Apr 15193 

727-52-0142 

6 
BOEING SERVICE BULLETIN 727-52-0142 

I. References 

1. Existing Data: 

a. 727 Maintenance Manual Subjects 52-11-0,52-34-0,52-34-11,52-34-161,52-34-171,52-70-00, 

52-70-01 

b. Overhaul Manual 52-36-61, 52-36-62 

c. 727 Structural Repair Manual Chapter 51 

d. Boeing Service BulleHns: 

o 727-29-0053 "Main Cargo Door Deactivation/Reactivation System Installation• 

o 727 -52A0124 "Main Cargo Door Cam Support Fitting Inspection and Replacement• 

e. Boeing Service Letters: 

o 727 -SL-52-4 "Main Cargo Door Pressure Door Locking Stops" 

o 727-SL-52-19 •Main Cargo Door Partial Opening In Flight" 

r. FAA Airworthiness Directive 91-22-04, Amendment39-8064 

2. Data supplied with this service bulletin: 

None 

J. Publications Changed 

Publication 

Overhaul Manual 

727 Illustrated Parts Catalog 

K. Electrical Load Data 

Not changed 

Jul26/90 

REV. 2: Apr 15/93 

Chapter-Section 

52-36 

52-30 

727-52-0142 

7 
BOEING SERVICE BULLETIN 727-52-0142 

II. MATERIAL INFORMATION 

A. Parts Necessary For Each Airplane 

1. To get \he kit shown below, refer to Paragraph I. F., Material- Price and Availability. 

NOTE: Top kit is divided Into subkits to make Installation of the parts easier. One 65-93535-9 top kit 

and operator supplied materials specified In Paragraph II.A.2 .. Parts and Materials Supplied 

by the Operator, are necessary to change each airplane. 

65-93535- KIT· MAIN CARGO DOOR LATCH CAMS AND LOCK FITTINGS 

-6 -5 -4 -3 -2 -1 

Quantily Part Number Nomenclature 

65-93535-1 Top Kil (a) 

1 65-93535-2 Kit, Latch Cams and Bellcrank 

Installation, Body Station 495 

65-93535-3 Kit, Latch Cams and Bellcrank 

Installation, Body Station 530 

65-93535-4 Kit. Latch Cams and Bellcrank 

Installation, Body Station 570 

65-93535-5 Kit, Latch Cams and Bellcrank 

Installation, Body Station 610 

2 65-93535-6 Kit, Pressure Relief Valve Hinge 

Installation. Body Stations 510 and 

590 

143N6027-1 Cam 

1 143N6027-2 Cam 

1 143N8060-1 Cam 

1 143N8060-2 Cam 

1 65-93535-7 Hinge Fitting 

1 65-93535-8 Hinge Fitting 

1 1 69-21969-11 Bellcrank 

1 69-21969-12 Bellcrank 

1 69-23438-1 Cam 

69-23438-2 Cam 

1 69-23439-3 Cam 

1 69-23439-4 Cam 

1 1 69-34974-3 Bracket. Lock Indicator 

1 69-34974-4 Bracket Lock Indicator 

1 1 AN960C616L Washer 

2 2 2 2 AN960PD8L Washer 

1 1 BACB30EL5CN19 Boll, Countersink 

3 6 6 3 BACW10P208S Washer 

Jul26/90 

REV. 2: Apr 15193 

727-52-0142 

8 
BOEING SERVICE BULLETIN 727-52-0142 

65-93535- KIT- MAIN CARGO DOOR LATCH CAMS AND LOCK FITTINGS 

-6 ·5 -4 ·3 ·2 ·1 

Quantity Part Number Nomenclature 

10 MS20470B8-14 Rivet 

3 6 6 3 NAS 11 04-20W Bolt 

1 1 NAS1105-20W Bolt 

1 1 1 1 NAS602-7 Screw 

1 1 1 NAS679A08W Nut 

3 6 6 3 NAS679A4W Nut 

2 2 NAS679A5 Nul 

(a) Top Klt 65-93535·1 Is held from more sales. Top Kll65·93535·9 replaces old top kit. 

65-93535- KIT· MAIN CARGO DOOR LATCH CAMS AND LOCK FITTINGS 

-6 -13 -12 -11 ·10 ·9 

Quantity Part Number Nomenclature 

65-93535·9 Top Kit 

1 65·93535-1 0 Kit, Latch Cams and Bellcrank 

Installation, Body Station 495 

1 65-93535-11 Kit, Latch Cams and Bellcrank 

Installation, Body Station 530 

1 65-93535-12 Kit, Latch Cams and Bellcrank 

Installation, Body Station 570 

1 65-93535-13 Kit, Latch Cams and Bellcrank 

Installation. Body Station 610 

2 65·93535-6 Kit, Pressure Relief Valve Hinge 

Installation, Body Stations 510 and 

590 

1 65-93535-20 Cam 

1 65-93535-17 Cam 

1 65-93535-14 Cam 

1 65-93535-22 Cam 

1 65-93535-7 Hinge Rttlng 

65-93535-8 Hinge FiHing 

1 1 65·93535-18 Bellcrank 

1 1 65-93535-15 Bellcrank 

1 65-93535-23 Cam 

1 65-93535-16 Cam 

1 65-93535-19 Cam 

Jul 26/90 

REV. 2: Apr 15/93 

727·52-0142 

9 
BOEING SERVICE BULLETIN 727-52-0142 

65-93535- KIT- MAIN CARGO DOOR LATCH CAMS AND LOCK FITTINGS 

-6 -13 -12 -11 ·10 -9 

Quantity Part Number Nomenclature 

1 65-93535-21 Cam 

1 1 69-34974-3 Bracket, Lock Indicator 

1 69-34974-4 Bracket, Lock Indicator 

1 1 AN960C616L Washer 

2 2 2 2 AN960PD8L Washer 

1 1 BACB30EL5CN 19 Bolt, Countersink 

3 6 6 3 BACW10P208S Washer 

10 MS20470B8-14 Rivet 

3 6 6 3 NAS1104-20W Bolt 

1 1 NAS 11 05-20W Bon 

1 1 1 NAS602-7 Screw 

1 1 1 1 NAS679A08W Nut 

3 6 6 3 NAS679A4W Nut 

2 2 NAS679A5 Nut 

2. Parts and Materials Supplied by the Operator: 

NOTE: Refer to 727 StnJctural Repair Manual Chapter 51 for alternative fasteners. 

Quantity 

50 

5 

7 

2 

16 

20 

20 

14 

16 

As Necessary 

As Necessary 

As Necessary 

2 

Jul26/90 

REV. 2: Apr 15193 

Part Number or 

Specification 

MS20470D6·7 

BACB30FP6-3 

BACB30FP6-4 

BACB30FP6-5 

BACB30FP8A( ) 

BACB30GYBA( )X 

BACC30K8 

BACC30M6 

BACC30M8 

BMS 10-11. Type I 

BMS 5-95, Class A and Class B 

MIL-G-23827 

Nomenclature 

Rivet. Universal Head 

HI-Lok 

Hi-Lok 

Hi-Lok 

Hi-Lok 

Lock bolt 

Collar 

Collar 

Collar 

Primer 

Sealant 

Grease 

1 inch long by 1.751nch diameter rod, 2024-T4 

or 6061-T4 aluminum. See Figure 2. 

727-52-0142 

10 
BOEING SERVICE BULLETIN 727-52.0142 

B. Parts Necessary to Change Spares 

None 

C. Special Tools and Equipment 

The special tool shown In Figure 2 of this bulletin c:an be made by the operator. Maintenance and 

overhaul tools c:an be necessary as given In any manuals that are listed In Paragraph 1.1., References, 

of this bulletin. Operators should review their tool inventory to make sure that tools are available. 

Jul26/90 

REV 2· Apr 15/93 

727-52-0142 

11 
BOEING SERVICE BULLETIN 727-52-0142 

D. Existing Parts Accountability 

The parts shown below are changed by this service bulletin. The Quantity Is the number of parts 

changed on each airplane. The Quantity of the indented part is the number of parts used on the next 

higher assembly. 

Installed Part 

Number Nomenclature 

65-25339-5 Latch Cam Assembly Of: 

Sta. 600 + 4.65 (Spares 

only) 

69-21971·4 Latch Cam 

69-23438-1 Latch Cam 

69-21969·3. -8, or -502 

Bellcrank Assembly 

65-25339-6 Latch Cam Assembly Of: 

Sta. 571.80 (Spares 

only) 

69-23439-3 Latch Cam 

69-23439-4 Latch Cam 

69-21969-1, -7, or Bellcrank Assembly 

-501 

65-25339-7 Latch Cam Assembly Of: 

Sta. 528.20 (Spares 

only) 

69-23439-3 Latch Cam 

69-23439-4 Latch Cam 

69-21969-2, -7, or Bellcrank Assembly 

-501 

65-25339-8 Latch Cam Assembly Of: 

Sta. 495.35 (Spares 

only) 

69-21971-3 Latch Cam 

69-23438-2 Latch Cam 

69-21969-4, -8, or Bellcrank Assembly 

-502 

65-26120-1, -3, Hinge, Pressure Valve 

or-5 

65-26120-2,-4, or Hinge, Pressure Valve 

-6 

69-21971-3 or -501 Latch Cam 

69-21971-4 or -502 Latch Cam 

69-23439-1 or ·3 Latch Cam 

69-23439-2 or -4 Latch Cam 

Jul 26/90 

REV. 2: Apr 15/93 

Qty DC New Part Number 

1 DIS 65-93535-13 

1 DIS 65-93535-22 

1 DIS 65·93535-23 

1 DIS 65·93535-15 

1 DIS 65-93535-12 

1 DIS 65-93535-20 

1 DIS 65-93535-17 

1 DIS 65-93535-18 

1 DIS 65-93535-11 

1 DIS 65-93535-20 

1 DIS 65-93535-17 

1 DIS 65-93535-18 

1 DIS 65-93535-10 

1 DIS 65-93535-14 

1 DIS 65-93535-16 

1 DIS 65-93535-15 

2 DIS 65-93535-7 

2 DIS 65-93535-8 

1 DIS 65-93535-14 

1 DIS 65-93535-22 

1 DIS 65-93535-20 

1 DIS 65-93535-17 

PNC 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

RC 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

727-52-0142 

12 
BOEING SERVICE BULLETIN 727-52-0142 

DC Disposition Code 

DIS Discard lhe part. 

PNC Part Number Code 

S This is lhe new equlvalenl or replacemenl part number. 

RC Replacemenl Code 

A Replacemenl nol permllted: Do nol replace a new part wllh an exisling part. 

Jul26/90 

REV. 2: Apr 15/93 

727-52-0142 

13 
Jul26/90 

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BOEING SERVICE BULLETIN 727-52-0142 

BLANK PAGE 

727-52-0142 

14 
BOEING SERVICE BULLETIN 727-52-0142 

Ill. ACCOMPLISHMENT INSTRUCTIONS 

NOTES: 

1. The paragraphs Identified with letters give the general wor1< Instructions and the necessary tests. 

The Instructions identified with numbers on the figures give the recommended sequence of steps. 

2. Unless specified differently, these dimensions and tolerances are used: 

- All linear dimensions are in inches 

- Tolerance on linear dimensions other than rivet and boll edge margin Is plus or minus 0.03 Inch 

- Angular tolerance is plus or minus 2 degrees 

- The hole dimensions for standard solid rivets are found In 727 Structural Repair Manual Chapter 51 

- The torque limits to tighten nuts and bolls are found in 727 Structural Repair Manual Chapter 51. 

3. Refer to 727 Structural Repair Manual Chapter 51 for alternative fasteners. 

4. Obey all warnings and cautions In the specified manual sections. 

PART I - INSPECTION 

A. Do an lnspecllon of the hinge fittings and the latch cams on the main cargo door as shown In Flgure 1. 

8 . If any or the four hinge fittings ara wom beyond the limit given In Flgure 1, Install new hinge fittings and 

latch cams In the main cargo door as specified In PART II - REPLACEMENT, below. 

C. If any of the four latch cams are wom or damaged as shown In Figure 1, Install new hinge fittings and 

latch cams In the main cargo door as specified In PART II - REPLACEMENT, below. 

PART II -REPLACEMENT 

A. Make the hinge fitting tools for the pressure relief doors as shown in Figure 2. 

8. Remove the interior lining and the insulation from the lower area or the main cargo door (Reference -

727 Maintenance Manual, Subjects 52-34-161 and 52-34-171). 

C. Put a wor1< platform next to the airplane at the main cargo door. 

D. Partially open the main cargo door. Use wood blocks to support the door In the partially opened 

position as shown In the 727 Maintenance Manual, Subject 52-34-0, Inspection/Check. Cycle the latch 

cams Into the locked position with the door In the open position as shown In the 727 Maintenance 

Manual Subject 52-34-0. 

E. Remove pressure from the hydraulic system for the main cargo door (Reference - 727 Maintenance 

Manual, Subject 52-11-0, Maintenance Practices). 

F. Remove the most forward and aft main cargo door latch actuators as shOwn in the 727 Maintenance 

Manual, Subject 52-11-11. 

G. Remove the web and access cover from each pressure rallef door location as shown In Figure 4. 

H. Remove the pressure ralief doors and carefully drill out the rivets that attach the hinge fittings to the 

pressure relief doors as shown In Figure 5, circle notes 1 through 9. 

I. Remove the latch cams and the bellcranks from the main cargo door, and install new latch cams and 

bell cranks as shown In Figure 3. 

Jul26190 

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15 
BOEING SERVICE BULLETIN 727-52-0142 

J. lnslallthe pressure relief door and locate lhe new hinge fillings on the pressure relief doors as shown in 

Figure 5, circle notes 10 through 26. 

K. Install the most forward and aft main cargo door latch actuators as shown In the 727 Maintenance 

Manual Subject 52-11-11. 

L. Operate the main cargo door as necessary to remove air from the hydraulic system for the main cargo 

door. Select door open control and open door sufficient to remove the wood blocks. Do not operate the 

main cargo door into the completely closed position while this step is done. 

M. Adjust the main cargo door as necessary and do a test of the main cargo door to make sure that II 

operates correcUy (Reference- 727 Maintenance Manual, Subject 52-34-0, AdlustmenVTest). 

NOTE: Inspect to make sure that the tab on the marking bracket Is inserted into the Index hole in the 

cam. Also do a check to see if the marking bracket is visible through the viewport in the cargo 

door skin when the door is closed and the latch cams are In the latched position. 

N. Do a lest of the warning system for the main cargo door to make sure thai II operates correcUy 

(Reference- 727 Maintenance Manual, Subject 52-70-00 or -01) 

0 . Do a test of the control system of the main cargo door to make sure that It operates correcUy. 

P. Install the web and access cover at each pressure relief door location as shown in Figure 6. 

Q . Install the insulation and the interior lining on the lower area of the main cargo door (Reference - 727 

Maintenance Manual, Subjects 52-34-171 and 52-34-161). 

R. Restore airplane to serviceable condition. 

Jul26/90 

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16 
BOEING SERVICE BULLETIN 727-52-0142 

Illustration Table of Contents 

Tille Page 

Figure 1. Inspection . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . • . . • . . . • . . . 18 

Figure 2. Alignment Tool Fabrication . . . . • . . . . . . . . . . . . . . . . . . . • . . . . . . . . • . . . . . . . . 20 

Figure 3. Latch Cam Replacement . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . • . . . . . . . . . . . 21 

Rgure 4. Web Removal . . . . . . . . . • . • . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . • . . • . . . . . 27 

Figure 5. Hinge Fitting Replacement. . .. . . • . . • . . .. . .. • .. . . . . . . .. .. . . . . . . . . . . .. 28 

Figure 6. Web Installation . . . . . . . . . . . . • . . . . . . . . • . . . . . . . . . . • . . . . . • . . . • . . . . . . . 32 

Jul26/90 727-52-0142 

REV. 2: Apr 15193 17 
ALMOST THE 

SAME AS DETAIL I 

< ' ~A HING E 

FITTING 

Jul26190 

REV 2: Apr 15/93 

BOEING SERVICE BULLETIN 727-52-0142 

SEE DETAIL I 

AS DETAIL 

CFVD 

~ INBD 

PRESSURE 

RELIEF 

DOOR 

TIP OF 

HINGE 2 

FITTING 

- -- --.....___ __ 

/ 

- 0.12 INCH 

MAXIMUII 

FLAT AllOWED 

FIGURE 1 INSPECTION 

VIEW A-A 

<2 PLACES) 

727-52-0142 

18 
BOEING SERVICE BULLETIN 727-52-0142 

() FIIO 

DETAIL I 

' LATCH 

CAM 

The Instruction numbers shown below agree With the numbers shown Inside the circle symbols In the figure: 

1 Do a visual Inspection or the area on each latch cam that contacts a hinge fitting on a pressure relief 

door (4 places). II the cam is notched as shown, or lithe cam shows any damage beyond 0.05 1nches 

deep from contact with the hinge fitting, replace the latch cams and the hmge fittings. 

2 Measure the tip or each hinge fitting as shown (4 places). II any ol the hinge fittings are worn beyond 

the limit shown, replace the latch cams and the hinge fittings as shown In this service bulletin. Reier to 

the 727 Maintenance Manual, Subject 52-34-0. 

NOTE: Removal ol the pressure relief door from the main cargo door may be necessary to do the 

inspection given In Step 2, above lnstructJons for removal ol the pressure relief door are given 

in the 727 Maintenance Manual, Subject 52-34-11 

3 II either the cam or the h1nge liWng Is worn. measure the overlap as shown in View AA Make sure that 

there is m1nimum of 0.15 inch overlap II there is less than a 0.15 1nch overlap, replace the cam and the 

hinge fittings as shown m this service bullebn. 

Jul26190 

REV, 2: Apr 15/93 

FIGURE 1. INSPECTION 

727-52-0142 

19 
A 

L 

0. 54 R 

0. 55 

BOEING SERVICE BULLETIN 727-52-0142 

)~ 

0. 84 R 

'/ 0.86 

A 

_j 

1 

0. 50 

B 

L 

1.0S OIA 

1 . 10 • 

B 

_j 

I 

0.50 

_L L__ __ ____J_L 

VIEW A-A VIEW B-B 

The instruction number shown below agree with the number shown inside the circle symbol in the figure. 

1 Make the two alignment tools to the dimensions shown from one or the materials given below: 

- 2024-T42 aluminum rod, 1.751nch outside diameter 

- 6061-T42 aluminum rod, 1.75 inch outside diameter. 

FIGURE 2. ALIGNMENT TOOL FABRICATION 

Jul 26/90 

REV. 2: Apr 15193 

727-52-0142 

20 
c: 

E 

Jul26/90 

SEE / 

DETAIL I 

DETAIL II 

REV. 2: Apr 15/93 

BOEING SERVICE BULLETIN 727-52-0142 

SEE 

DETAIL VI 

SEE 

DETAIL V 

e!> FWD 

~ INBD 

FIGURE 3. LATCH CAM REPLACEMENT 

Ill 

CARG O 

DOOR 

I 

II 

727-52-0142 

21 
Jul26/90 

REV. 2: Apr 15/93 

BOEING SERVICE BULLETIN 727·52-0142 

CFWO 

DETAIL I 

AFT LATCH CAM ANO BELLCRANK ASSEMBLY SHOWN, 

FORWARD LATCH AND BELLCRANK ASSEMBLY OPPOSITE 

SHEAR VEB 

69-24209-() ..... 

' '-· I ', 

_,_ 

DETAIL II 

VIEW LOOKING FORWARD 

c:::> INBD 

AFT LUG ASSEMBLY SHOWN, FOR WARD LUG ASSEMBLY OPPOSITE 

FIGURE 3. LATCH CAM REPLACEMENT 

727 ·52·0142 

22 
BOEING SERVICE BULLETIN 727-52-0142 

6 69- 34974-3 

(!A 

Jul26/90 

REV. 2: Apr 15/93 

7 

6 

DETAIL Ill 

,

65-93535-1 9[3; 69- 34974-4 6 

'-1- LATCH 

(~ ACTUATOR 

5 ~ 

~ l-~~ ~l@l J jiX£9J 

. ~ '@ I)!) ,,_,,,_" ,v)1c~ 0 )~{~ I 

BELLC RANK. e«'~lfA_ '- -~ 

'-1! "-> r ~~' •t- ·W d 21\\ ~if& ~ ..v '~ "'-,)> f wo 

DETAIL IV 

FIGURE 3. LATCH CAM REPLACEMENT 

727-52-0142 

23 
Jul26190 

REV. 2: Apr 15/93 

BOEING SERVICE BULLETIN 727-52-0142 

FIGURE3 · LATCHCA M REPLACEMENT 

727-52-0142 

24 
BOEING SERVICE BULLETIN 727-52-0142 

VIEWPORT 

DOOR 

SKIN-. 

- c) I NBD 

VIEW A-A 

_,.! KARKING 

BRACKET 

LATCH CAK 

The instructions given below apply to lalch cams and bellcranks located at Body Stallons 495, 530, 570. 

and 610. See Details I, 11. Ill, and VI for complete figures that show replacement of the forward and aft latch 

cam and bellcrank assembly. See details IV and V for complete figures that show replacement of the latch 

cam and bellcrank assembly located at Body Station 530 and 570. The Instructions given below agree with 

the numbers shown inside the circle symbols In the figure: 

1 For the most forward and aft latch cam, tnm the shear web 69-24209-( ' ) and extend the cut out of the 

lower beam web and doubler 65-25338-( • ) Inboard, up to the maximum amount as shown. Do not trim 

shear web or extend the cut out of the lower beam web beyond what Is necessary for the removal of the 

lug assembly. Maintain 0.50 R or larger comer radius. On the aluminum shear web 69-24209-3, -4 and 

the lower beam web and doubler 65-25338-( • ), finish lrinvned areas with brushed on chemical film 

treatment (Nodine or lridite), and one coat of BMS 10-11 Type I primer Touch up w.th one coat of 

deoorabve enamel. On steel shear web 69-24109-7 and -8, finish trimmed areas w.th brush cadmium 

plate and one coal of BMS 10-11 Type I pnmer Touch up with one coat of decorative enamel. 

2 Remove the fasteners that attach the Lug Assembly 9-66095-1 and -2 lo lhe frame. 

3 Remove the special bolt that attaches tho latch actuator to the bellcrank. Keep the special bolt and 

hardware for later use. 

NOTE: If the special bolt is worn. corroded, or is missing finish. use a new Boll 66-17789-1. 

4 Remove and discard lhe fasteners that auach lhe bellcrank to lhe latch cams 

5 Remove lhe bellcrank and the latch cams from lhe door, and dJscard the bellcrank and the latch cams. 

Jul26/90 

REV 2: Apr 15193 

FIGURE 3. LATCH CAM REPLACEMENT 

727-52-0142 

25 
BOEING SERVICE BULLETIN 727-52-0142 

6 Use a screw NAS602-7, two washers AN960PD8L and a nut NAS679A08W to Install the marking 

bracket on the new latch cam. Make sure that the tab on the marking bracket fils into the index hole on 

the cam. Make sure that the marking bracket Is visible through the viewport in the cargo door skin 

when the door is closed and the latch cams are in the latched position. 

CAUTION: Make sure that the correct marking bracket is Installed on each cam as shown In Figure 3. 

There are two different part numbered marking brackets. If the wrong bracket is Installed 

on the cam, it will not be visible through the viewport In the cargo door skin when the door 

Is In the latched position, 

7 Apply a thin coat of grease MIL-G-23827 (or equivalent) to the bearing surfaces of the new latch cams 

and the new bellcrank. 

8 Apply primer (Reference - BMS 10-11, Type I) to the tapered end of bellcrank. Do not allow the primer 

to dry before the next step Is done. 

9 Use the fasteners indicated to Install the new latch cams and the new bellcrank In position on the cargo 

door. 

NOTE: Make sure that the forward and all lug assembly are in place prior to installing the most 

forward and aft latch cams and bellcrank. 

10 Attach the latch actuator to the new bellcrank. Use the special boll and hardware that was kept when 

the instructions given In Step 3, above, were done. Torque the bolt with 50 to 80 Inch-pounds. 

11 Install the Lug Assembly to the web. (Refer to 727 Structural Repair Manual 51-30-05). 

The Instructions given below agree with the letter shown in the upper-left comer of the fastener symbols in 

the figure. A number In the lower-right comer or the fastener symbol is the length or the fastener. 

A Install a bolt NAS11 04-20W with a washer BACW1 OP208S under the boll head. Use a nut 

NAS679A4W to secure the boll. and torque the nut with 50 to 80 Inch-pounds. 

B Install a boll NAS1105-20W with a washer AN960C616L under the bolthead. Use a nut NAS679A5 to 

secure the boll, and torque the nut with 100 to 150 inch-pounds. 

C Install a countersink bolt BACB30EL5CN19 with a nut NAS679A5. Torque the nut with 60 to 65 

inch-pounds. 

D Install BACB30GYBA( )X Lockbolt with a BACC30K8 Collar. 

FIGURE 3. LATCH CAM REPLACEMENT 

Jut26190 

REV. 2: Apr 15/93 

727-52-0142 

26 
BOEING SERVICE BULLETIN 727-52-0142 

e>FWD 

~ INBD 

The lnstruct1on numbers shown below agree with the numbers shown InSide the circle symbols In the figure. 

1 Remove and keep the screws that attach the access panel for lhe pressure relief door, and remove and 

keep the access panel for later use 

2 Drill out or otherwise remove all fasteners that attach the web to lhe structure around the pressure relief 

door. 

3 Remove and keep the web for later use 

FIGURE 4 WEB REMOVAL 

Jul26190 

REV 2 Apr 15/93 

727-52-0142 

27 
Jul26/90 

SEE DETAIL I 

FOR DOOR 

EXTERN AL 

VIEW~ 

STA 

480 

REV. 2: Apr 15/93 

BOEING SERVICE BULLETIN 727-52-0142 

O FWD 

~ INBD 

SEE DETAIL II 

STA 

600D 

______ I 

00000 

= L~~u ---..j-' 

DETAIL I 

DOOR EXTERNAL VIEW 

A 

~ 

FIGURE 5. HINGE FITTING REPLACEMENT 

727-52-0142 

28 
NUT 

7 113 

--18123 

Jul26/90 

BOEING SERVICE BULLETIN 727-52-0142 

5) 24 

6 J)i9•,!YE@_ PRESSURE RELIEF DOOR .._ 

.• A cf .... -l v!JfB 

~~~ ( ~ ~8 ~~ 8 v.y . .:> 

j, ...._ _J !j i4 HINGE FITTING 

c 

I 

(!; FVO 

DET AI L II 

J 

SECTION B-B 

(2 PLACES> 

(9_@, HINGE FITTI NG 

HINGE BOLT 

8ELLCRANK 

SECTION A- A 

VIEW C-C 

(2 PLACES) 

16121 ~ 

..,..1_2 19 

ALIGN"ENT 

TOOLS 

FIGURE 5. HINGE FITIING REPLACEMENT 

REV. 2. Apr 15/93 

727-52·0142 

29 
BOEING SERVICE BULLETIN 727-52-0142 

The Instruction numbers shown below agree with the numbers shown Inside the circle symbols in the figure. 

1 Make sure thai the pressure relief door is closed and seated against Its cutout In the main cargo door. 

2 Make marks on the outside of the pressure relief door and on the outside of the cargo door skin with a 

marker that will not damage the pressure relief door or the cargo door skin. Make sure that the marks 

on the pressure relief door are aligned with the marks on the cargo door skin. These marks will be used 

later to correcUy position the pressure relief door on the cargo door when the new hinge fittings are 

installed as described in Step 16, below. 

3 At the aft pressure relief door location only, remove the hydraulic tubes that are located Inboard of the 

pressure relief door. T emporarlly plug or cap the open hydraulic tubes to make sure that hydraulic fluid 

does not spill in the pressure relief door area in the cargo door. 

4 Remove the nut, the bolt, the washers and the spacers from the bellcrank on the torque tube that is 

above the pressure relief door. Keep all of this hardware for later use. 

5 Remove the nut, the washer, and the bolt from the bellcrank on the torque tube that Is above the 

pressure relief door. Keep all or this hardware for later use. 

6 Rotate the bellcrank on the torque lube so that it Is out of the way of the pressure relief door. 

7 Remove the nut, the special bolt, the washers, and the spacer from the hinge points of the pressure 

relief door. Keep all of this hardware for later use. 

8 Remove the pressure relief door from the cargo door. 

9 Carefully drill out the rivets thai attach the hinge fittings to the pressure relief door. Discard the old 

hinge fittings. 

10 Put the pressure relief door Into the cargo door and align the marks on the pressure relief door with the 

marks on the cargo door skin. 

1 1 Wedge the pressure relief door so that it is firmly seated in its cutout on the cargo door. 

NOTE: Make sure that the outside surface of the pressure door Is flush with the outside skin or the 

main cargo door. Refer to the 727 Maintenance Manual, Subject 52-34-1 1. 

12 Put the alignment tools that were made In Figure 2 inside the cup of the cam as shown. 

13 Attach the new hinge fittings 65-93535-7 (art) and 65-93535-8 (forward) to the pivot points with the 

hardware that was kept when Step 7, above, was done. Make sure that all of the hardware is installed 

exactly like It was before it was removed. 

14 Make sure that the new hinge fittings tum freely on the special bolt, and that the mating surfaces of the 

hinge fittings and the pressure relief door are in contact with each other. 

Jul26/90 

REV. 2: Apr 15/93 

FIGURE 5. HINGE FITTING REPLACEMENT 

727-52-0142 

30 
I 

BOEING SERVICE BULLETIN 727-52-0142 

15 Rotate the h1nge fittings until the bp touches the alignment tool as shown. 

t!Q!S; Make sure that there Js no Interference between the cam and the hinge fitt1ng. If the hinge 

fitting Interferes with the cam. then do the steps that follow: 

a. Trim up to a maximum of 0.05 Inch from the outboard surface on the hinge fitting. Make 

sure that the removal of malarial Is done so to main lain the radius of the part. Maintain a 63 

AA surface finish or better. 

b. Finish filed area with two coats of BMS 10-11 Type I primer. 

c. Conlact Boeing If a trim of 0.05 does not stop the Interference. 

16 Tlghtly clamp the hinge fittings to the pressure relief door and remove the wedges that held the 

pressure relief door In position In the cargo door. 

17 Make sure that the pressure relief door moves freely with the new hinge fiwngs 

18 Remove the nut. the special bolt. the washers, and the spacer from the hinge poonts of the pressure 

relief door. Keep all of this hardware for later use. 

19 Remove the pressure relief door from the cargo door. and remove the alignment tools from cup of the 

cam. Make sure that the new hinge fittings are not moved out of the clamped position when the 

pressure relief door Is removed. 

20 Carefully drill matching 0.257 Inch diameter (drill Size "F") holes In the new hinge fittings at locations 

where fastener holes exist In the pressure relief door. Use of a drill bushing to make 1/8 Inch diameter 

pilot holes In the new hinge fittings Is recommended, followed by gradual enlargement of the fastener 

holes to the final size. 

NOTE: As an option, the operator may use HI·Loks BACB30FP8A( ) and collars BACC30M81n place 

of rivets to inslall the hinge fitting to the pressure door. To use HI·Loks Carefully dnll matching 

0.266 to 0.270 Inch diameter holes In the new hinge fittings at the locations where fasteners 

holes exist in the pressure rel1ef door. 

21 Remove the new h1nge fittings from the pressure relief door and deburr all fastener holes In the hinge 

fittings. 

22 Use rivets MS204 7088-14 or optional fasteners coated With sealant (Reference • BMS 5-95, Class A) to 

lnslall the new hinge fittings on the pressure relief door. 

23 Put the pressure relief door In position In lhe cargo door and attach lhe hinge filbngs to the pivot points 

with the hardware that was kept when Step 18, above. was done. Make sure that all of the hardware Is 

Installed exactly like It was before It was removed, and make sure that the pressure relief door moves 

freely on Its hinges. Torque the nut with 50 to 80 Inch-pounds. 

24 Rolate the bellcrank on the torque tube that Is above the pressure relief door Into correct position on the 

torque tube and attach the bellcrank to the torque tube with the hardware that was kept when Step 5, 

above, was done. Torque the nul With 25 to 35 Inch-pounds. 

25 Use the hardware that was kept when Step 4. above, was done to attach the bellcrank to the slotted 

bracket on the pressure relief door Torque the nut With 25 to 35 tnch-pounds 

26 Install the two hydrauf](; tubes that were removed when Step 3. above, was done 

FIGURE 5. HINGE FITTING REPLACEMENT 

Jul26/90 

REV 2· Apr 15/93 

727-52-0142 

31 
BOEING SERVICE BULLETIN 727-52-0142 

SEE DETA IL II 

I 3 L ~ -- A ![-- _a _ 4 

~ 

r L \.-- !fL-r--" 

...., 1 I Z 

-

0 

; 

: 

Jul 26190 

REV. 2: Apr 15/93 

OFWD 

~ INBD 

SEE DETAIL 1 

';) ( 14 PLACES) r~ - -----i--t--- ~ 

•t- 81 8 •-t- + L at· •t A ,; 

5 ..t A 

g 0 0 0 ' l 0\ A 

) 

0 @ A 

) 

A 

0 

~ ) 

At l l 

0 0 0 0 (II 'Z) 

'-

Bf 81 91 8+ ~ !t , a• r 

3 (Z4 PLACES) 

DETAI L 1 

FIGURE 6 WEB INSTALLATION 

727 -52..{)142 

32 
BOEING SERVICE BULLETIN 727-52-0142 

(})'1) 1\ 

CD (1 4 PLACES) 

T 

~ \ 

4s !_h + 

y 

at Bl-

.._ 

Bt- 81- 4 -4 + + -~ + A4 

lfr 0 ® 0 e rf' 4 

lfr + lfr e e 

~ !JJ_l e ® 

~'I- 0 "-- e 0 0 ~ 

*- 4 4 !J- B. Bf- Bt [' T 

I 

{_ 

' 

L""'" ciflJ 

DETAIL II 

The instruction numbers shown below agree wilh the numbers shown inside the circle symbols In the figure. 

1 Clean all old sealant from mating surfaces of the web and the cargo door structure. 

2 Apply sealant (Reference - BMS 5-95, Class B) to mating surfaces of web and cargo door structure. Do 

not allow the sealant to dry before the next step is done. 

3 Use the fasteners listed below at each pressure relief door location to Install the webs that were kept 

when the instructions In Agure 3 were done. 

4 Use the screws that were kept when Agure 3 was done to Install the access cover on the web. 

The instruc«ons given below agree with the tetter shown in the upper-left comer of the fastener symbols in 

the figure. A number in the lower-right corner of the fastener symbol is the length of the fastener. 

A Drill fastener holes In web and cargo door structure to 0.200 (+ 0.003 or - 0.000) Inch diameter. Install 

a Hi-Lok BACB30FP6·() wllh a collar BACC30M6. 

8 Install a rivet MS20470D6-7 (24 Places). 

FIGURE 6. WEB INSTALLATION 

Jul26/90 

REV. 2: Apr 15/93 

727-52-0142 

33 

IIDIIND 

Number: 727-52-0142 

Date: July 26, 1990 

Revision 2: April15, 1993 

ATA System: 5234 

Prepared By: Mark Miller 

Commercial 

Airplane 

Group 

727 

Service Bulletin 

Evaluation Form 

SUBJECT: DOORS- MAIN CARGO DOOR- LATCH CAM REPLACEMENT AND PRESSURE RELIEF 

DOOR HINGE FITTING REPLACEMENT 

Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data 

that you give us to improve the quality of our service bulletlns. Please Include data about these or other 

items: 

- Did this service bulletin meet your estimate of quality? 

- How easy is this service bulletin to understand? 

- Are the Planning Information, Material Information and Accomplishment Instructions satisfactory? 

- Wilt you do this service bulletin fully? If not, please tell us why. 

- Is the Manpower estimate satisfactory? 

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these 

changes, please use e Publication Change Request (PCR) form. 

Please give us this data: 

OPERATOR: 

PREPARED BY: 

ORGANIZATION: 

TELEPHONE NUMBER: 

COMMENTS: 

TODAY'$ DATE: -------

TITLE: 

TELEX CODE: 

If you have other comments please use the other side. Thank you for the time you used to complete this 

form. 

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form 

directly to this address: 

R.G. Kelsey, Manager 

Service Bulletin Engineering 

Boeing Commercial Airplane Group 

P.O. Box 3707, Mall Stop 2L-02 

SeatUe, WA 98124-2207 

BOEING COMMERC.Al NRPL.AIIIE GROUP P.O. BOX 3707 SEATTLE. WASHINGTON 981244 2207