### Commercial Airplanes 

# 707 Service Bulletin ALERT Number: A3536 Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2012 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 1 of 82 4.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 2 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT

BLANK PAGETable of Contents Revision Transmittal Sheet............................................ 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 G. Manpower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1. Existing Data:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 27 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 27 K. Publications Affected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 28 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. Industry Support Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 29 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 31 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION. . . . . . . . . 39 FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT. . . . . 42 FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT. . . . . . . . . . . . 44 FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION. . . . . . . . 46 FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT. . . . . . . . . . . 48 FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT. . . . . . . . . . . . . . . . . . . 50 FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT. . . . . . . . . . . . . . . . . . . . 53 FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION. . . . . . . . . . . 55 FIGURE 9: MAIN CARGO DOOR - CAM LATCHES, LATCH PINS AND LATCH PIN CROSS BOLTS INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 3 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING. . . . . . . . . . . . . 60 FIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT . . 63 APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST. . . . . . . . . . . . . . . . . . . . . . . . . 65

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 4 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT

### Commercial Airplanes 

# 707 Service Bulletin ALERT Revision Transmittal Sheet Number: A3536 Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification This revision includes all pages of the service bulletin. COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2012-NM-132-AD, is related to this service bulletin. Effects of this Revision on airplanes on which Original Issue was previously done:
None. REASON FOR REVISION This revision is sent to clarify the requirements of the compliance tables. These sections were changed: 1. Summary - BACKGROUND: Text revised to include more detailed information. Summary Evaluation Table revised to reflect this revision. 2. Summary - ACTION: Text revised to include more detailed information. 3. Summary - Compliance: Notice of Proposed Rule Making (NPRM) statement added. 4. Summary - Graphic: Illustration revised to align with the changes made in this revision. 5. Paragraph 1.C. Reason: Text revised to include more detailed information. 6. Paragraph 1.D. Description: Text revised to include more detailed information. 7. Paragraph 1.E. Compliance: NPRM statement added. Compliance Tables 1 and 2 revised to clarify inspections, conditions and actions. 8. Paragraph 1.G. Manpower: Footnote in table revised to show NDI inspection. 9. Paragraph 1.H. Weight and Balance: Table added to show the 707-300/-300B/-300C airplanes.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 5 of 8210. Paragraph 1.K. Publications Affected: Added a table to show the different publications affected, and DTI statement added. 11. Paragraph 1.M. Software Accomplishment. Added. 12. Paragraph 2.C.2. Parts and Materials Supplied by the Operator: Added footnote (g). 13. Paragraph 3.A. General Information: Added new information. 14. Paragraph 3.B. Work Instructions: Revised to show new conditions and text. 15. Figures 1 thru 9: Illustrations and step tables revised to align with the changes made in this revision. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes. Pages with no vertical lines have no changes. REVISION HISTORY February 06, 2012 Original Issue: September 16, 2015 Revision 1:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 6 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT

### Commercial Airplanes 

# 707 Service Bulletin ALERT Summary Number: A3536 Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements. BACKGROUND Accomplishment of the inspections in this service bulletin will make sure the Main Cargo Door (MCD) cam latches are inspected for damage and the latch pins are inspected for damage and migration. The inspections are necessary in order to find and replace damaged cam latches, latch pins and latch pin cross bolts. If not replaced, damaged cam latches, latch pins and latch pin cross bolts could lead to a failure of the cam latches and may result in a possible rapid decompression and potential separation of the main cargo door from the airplane. Boeing has received one report from one 757 operator that the MCD forward most cam latch on the forward center cam latch pair (cam latch number 3) broke during flight. The 757 airplane with the reported broken cam latch had accumulated 20,000 flight hours and 9,500 flight cycles when the cam latch broke. The crew heard a loud noise coming from the MCD shortly after reaching cruise. Upon landing, an inspection was performed and a cam latch was found broken. The broken cam latch mating latch pin was also found to have significant wear as evidenced by the loss of the plating on the surface that is normally in contact with the cam latch. The latch pin was also deformed approximately 0.05 inch in the area of the wear surface. The latch pin cross bolt was unserviceable. The 707 MCD is of similar design to the 757 MCD. Boeing has not received any reports of a broken cam latch on a 707 MCD. The cause of the broken cam latch has been determined to be from a poorly rigged MCD. Although properly rigged per the original Aircraft Maintenance Manual (AMM) procedures, significant variation was allowed in the rigging dimensions. This variation can cause some of the latch pin/cam latch locations to have a significant preload placed on them during engagement and rotation of the cam latches during latching and unlatching operations. This preload is believed to have imparted a torque on the latch pin from the cam latch rotation during latching and unlatching operations. The torque transmitted to the latch pin is then believed to have caused the latch pin cross bolt to fail in shear.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 7 of 82If the latch pin cross bolt fails, the latch pin could migrate either towards the cam latch or away from the cam latch. Latch pin migration towards the cam latch can cause significant interference with the mating cam latch leading to cam latch damage. In the 757 case, the latch pin migrated into the cam latch and caused damage to the cam latch. The crack initiated at the damage site caused by the latch pin and then led to the cam latch breaking. Latch pin migration away from the cam latch could cause disengagement from the cam latch, resulting in no load transfer between the cam latch and the mating latch pin and may not be noticed before critical conditions are exceeded in adjacent cam latches or latch pins. Accomplishment of the work given in this service bulletin will make sure the cam latches, latch pins and latch pin cross bolts are inspected and repaired or replaced as required. The MCD rig will be verified to the Service Bulletin requirements. Boeing Service Related Problem (SRP) 707-52-0088 is related to this service bulletin. Boeing Fleet Team Digest (FTD) 707 FTD 52-09001 is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Reference Affected Planning Data Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected Yes Publications Affected Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin Yes Special Tooling Required

ACTION Get access to the MCD. Do a general visual inspection of the cam latches, latch pins and latch pin cross bolts. Torque the cross bolts in the latch pins. Measure the extension of the latch pins. Replace all alloy steel cross bolts through the latch pins with Corrosion Resistant Steel (CRES) cross bolts. Check for lip deformation on all cam latches. Do a High Frequency Eddy Current (HFEC) or magnetic particle inspection of cam latch 1 and cam latch 2 for cracks. Replace any cracked or broken parts. Check the rig of the MCD and do the latch mechanism adjustment test to the requirements of the Service Bulletin. Do repetitive general visual and detailed inspections of the cam latches and latch pins after the rig is verified or adjusted. Do repetitive HFEC or magnetic particle inspections of cam latch 1 and cam latch 2 for cracks after the rig is verified or adjusted.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 8 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTEFFECTIVITY 707-300, 707-300B and 707-300C airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2012-NM-132-AD, is related to this service bulletin. Refer to Paragraph 1.E., Compliance. INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections and modifications given in this service bulletin. MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 9 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTExport Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 10 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT

### Commercial Airplanes 

# 707 Service Bulletin ALERT Number: A3536 Original Issue: February 06, 2012 Revision 1: September 16, 2015 ATA System: 5211 SUBJECT: DOORS - Main Cargo Door - Cam Latch and Latch Pin Inspection and Modification
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity 1. Airplanes Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, LineNumber, and Serial Number data.
DESCRIPTION CONFIGURATION GROUP 707-300, 707-300B and 707-300C airplanes with a Main Cargo Door

- 1

Airplane Models: 707-300, 707-300B, 707-300C Group Variable Number 1 02017 1 05601 - 05605 1 06461 1 07001 - 07017 1 07041 - 07059 1 07071 - 07081 1 07101 - 07109 1 07181

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 11 of 82Group Variable Number 1 07191 1 07201 - 07215 1 07251 - 07271 1 07401 - 07407 1 07451 - 07458 1 07501 - 07504 1 07601 - 07626 1 07661 - 07662 1 07681 - 07684 1 07701 - 07702 1 07801 - 07821 1 07901 - 07907 1 08001 - 08008 1 08021 1 08051 - 08056 1 08071 - 08077 1 08101 - 08104 1 08121 - 08129 1 08141 - 08144 1 08151 - 08153 1 08171 - 08173 1 08191 - 08192 1 08201 - 08210 1 08221 - 08224 1 08241 - 08244 1 08251 1 08261 1 08271 1 08301 - 08320 1 08324 - 08330 1 08333 1 08401 - 08410 1 08451 - 08452

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 12 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTGroup Variable Number 1 08471 - 08475 1 08501 - 08502 1 08551 - 08553 1 08581 - 08582 1 09001 - 09006 1 09101 - 09107 1 09161 - 09167 1 09201 - 09204 1 09221 - 09223 1 09227 1 09231 - 09232 1 09251 1 09271 1 09281 1 09286 - 09290 1 09411 1 09421 1 09438 1 09441 2. Spares Affected
None. B. Concurrent Requirements
The service bulletin listed below must be done in accordance with FAA Airworthiness Directive AD 91-22-04. If the service bulletin below has not previously been accomplished as required by AD 91-22-04, then it must be accomplished before further flight. Description Service Bulletin Company Replaces the latch cam and the pressure relief door hinge fitting on the main cargo door. 707-3477 Revision 2. (a) The Boeing Company

(a) The work given in Boeing Service Bulletin 707-3477 Revision 2 is necessary to comply with FAA Airworthiness Directive AD 91-22-04.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 13 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTC. Reason Accomplishment of the inspections in this service bulletin will make sure the Main Cargo Door (MCD) cam latches are inspected for damage and the latch pins are inspected for damage and migration. The inspections are necessary in order to find and replace damaged cam latches, latch pins and latch pin cross bolts. If not replaced, damaged cam latches, latch pins and latch pin cross bolts could lead to a failure of the cam latches and may result in a possible rapid decompression and potential separation of the main cargo door from the airplane. Boeing has received one report from one 757 operator that the MCD forward most cam latch on the forward center cam latch pair (cam latch number 3) broke during flight. The 757 airplane with the reported broken cam latch had accumulated 20,000 flight hours and 9,500 flight cycles when the cam latch broke. The crew heard a loud noise coming from the MCD shortly after reaching cruise. Upon landing, an inspection was performed and a cam latch was found broken. The broken cam latch mating latch pin was also found to have significant wear as evidenced by the loss of the plating on the surface that is normally in contact with the cam latch. The latch pin was also deformed approximately 0.05 inch in the area of the wear surface. The latch pin cross bolt was unserviceable. The 707 MCD is of similar design to the 757 MCD. Boeing has not received any reports of a broken cam latch on a 707 MCD. The cause of the broken cam latch has been determined to be from a poorly rigged MCD. Although properly rigged per the original Aircraft Maintenance Manual (AMM) procedures, significant variation was allowed in the rigging dimensions. This variation can cause some of the latch pin/cam latch locations to have a significant preload placed on them during engagement and rotation of the cam latches during latching and unlatching operations. This preload is believed to have imparted a torque on the latch pin from the cam latch rotation during latching and unlatching operations. The torque transmitted to the latch pin is then believed to have caused the latch pin cross bolt to fail in shear. If the latch pin cross bolt fails, the latch pin could migrate either towards the cam latch or away from the cam latch. Latch pin migration towards the cam latch can cause significant interference with the mating cam latch leading to cam latch damage. In the 757 case, the latch pin migrated into the cam latch and caused damage to the cam latch. The crack initiated at the damage site caused by the latch pin and then led to the cam latch breaking. Latch pin migration away from the cam latch could cause disengagement from the cam latch, resulting in no load transfer between the cam latch and the mating latch pin and may not be noticed before critical conditions are exceeded in adjacent cam latches or latch pins. Accomplishment of the work given in this service bulletin will make sure the cam latches, latch pins and latch pin cross bolts are inspected and repaired or replaced as required. The MCD rig will be verified to the Service Bulletin requirements. Boeing Service Related Problem (SRP) 707-52-0088 is related to this service bulletin. Boeing Fleet Team Digest (FTD) 707 FTD 52-09001 is related to this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 14 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTD. Description Get access to the MCD. Do a general visual inspection of the cam latches, latch pins and latch pin cross bolts. Torque the cross bolts in the latch pins. Measure the extension of the latch pins. Replace all alloy steel cross bolts through the latch pins with Corrosion Resistant Steel (CRES) cross bolts. Check for lip deformation on all cam latches. Do a High Frequency Eddy Current (HFEC) or magnetic particle inspection of cam latch 1 and cam latch 2 for cracks. Replace any cracked or broken parts. Check the rig of the MCD and do the latch mechanism adjustment test to the requirements of the Service Bulletin. Do repetitive general visual and detailed inspections of the cam latches and latch pins after the rig is verified or adjusted. Do repetitive HFEC or magnetic particle inspections of cam latch 1 and cam latch 2 for cracks after the rig is verified or adjusted. Revision 1 - Effects of this Revision on airplanes on which Original Issue was previously done:
None. The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones Zone Model 2-49 707-300, 707-300B, 707-300C E. Compliance The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2012-NM-132-AD, is related to this service bulletin. If all Table 1 requirements, including rigging of the main cargo door, have been accomplished in accordance with the original issue of this service bulletin, continue repetitive inspections in accordance with Table 2. If Table 1 requirements have not been accomplished in accordance with the original issue of this service bulletin, then all Table 1 requirements, including rigging of the main cargo door, must be accomplished before starting Table 2 requirements. Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 15 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition

- Within 150 days after the original issue date ofthis service bulletin. Within 330 flight cycles after the original issuedate of this service bulletin. Do the following for all MCD cam latches and latch pins:Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts, and for any missing cam latches, latch pins and latch pin cross bolts in accordance with Step 1.b. All airplanes

AND Torque the cross bolts inthe latch pins in accordance with Step 1.c. AND Measure the extension ofthe latch pins in accordance with Step 1.d. ANDDo a general visual inspection of all cam latches for lip deformation in accordance with Step 1.e.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 16 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition

- Before further flight Replace broken and missing cam latches, latch pins and latch pin cross bolts in accordance with Step 2.a. Condition 1: One or more of the following is found: 1. Broken or missing cam latch(es). 2. Broken or missing latch pin(s). 3. Broken or missing latch pin cross bolt(s). AND Do a detailed inspectionof mating part(s) and immediately adjacent cam latch(es) and latch pin(s) for any cracks, or any gouges in critical areas in accordance with Step 2.b. AND Unless replaced with new or reworked parts,do aHFEC or magnetic particle inspection of cam latch 1 and cam latch 2for any cracks in accordance with Step 2.c. (b) AND Check the rig of the MCDand do the latch mechanism adjustment test in accordance with Step 2.d. AND Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 2.d.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 17 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition

- Within 150 days after the latch pin extension was measured. Within 330 flight cycles after thelatch pin extension was measured. Replace the discrepant latch pin in accordance with Step 3.a. AND Do a detailed inspection of the mating cam latch for any cracks, or gougesin critical areas in accordance with Step 3.b. Condition 2: The latch pin extension is less than 0.89 inches or greater than 0.91 inches.

330 flight cycles or 150 days, whichever occurs first. (a) - - Do the following for all MCD cam latches and latch pins:Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts, and for any missing cam latches, latch pins and latch pin cross bolts in accordance with Step 3.c. AND

- Within 24 months after the original issuedate of this service bulletin. Within 3,000flight cycles after the original issue date ofthis service bulletin. Do a detailed inspection of all latch pin(s) and mating cam latch(es) for any cracks, or gouges incritical areas in accordance with Step 3.d.

- Within 24 months after the original issuedate of this service bulletin. Within 3,000flight cycles after the original issue date ofthis service bulletin. Unless replaced with new or reworked parts, do aHFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 3.e. (b) AND Check the rig of the MCDand do the latch mechanism adjustment test in accordance with Step 3.f. AND

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 18 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition
Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 3.f.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 19 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition 330 flight cycles or 150 days, whichever occurs first. (a) Within 150 days after the initial inspection. Within 330 flight cycles after the initial inspection. Do a detailed inspection of the discrepant cam latch and mating latch pin for any cracks, or gougesin critical areas in accordance with Step 4.a. Condition 3: If a cam latchis found with lip deformation.

AND 330 flight cycles or 150 days, whichever occurs first. (a) - - Do the following for all MCD cam latches and latch pins:Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts, and for any missing cam latches, latch pins and latch pin cross bolts in accordance with Step 4.b. AND

- Within 24 months after the original issuedate of the service bulletin. Within 3,000flight cycles after the original issue date of the service bulletin. Do a detailed inspection of all latch pin(s) and mating cam latch(es) for any cracks, or gouges incritical areas in accordance with Step 4.c. AND

- Within 24 months after the original issuedate of the service bulletin. Within 3,000flight cycles after the original issue date of the service bulletin. Unless replaced with new or reworked parts, do aHFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 4.d. (b) AND Check the rig of the MCDand do the latch mechanism adjustment test in accordance with Step 4.e. AND

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 20 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition
Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 4.e. 330 flight cycles or 150 days, whichever occurs first. (a) - - Do a general visual in- spection for any broken or missing cam latches, latch pins and latch pin cross bolts in accordance with Step 5.a.Condition 4: No discrepancies found (c)

3,000 flight cycles or 24 months, whichever occurs first. (a) Within 24 months after the initial inspection. Within 3,000flight cycles after the initial inspection. Do a detailed inspection of the cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with Step 5.b. AND Unless replaced with new or reworked parts, do aHFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 5.c. (b)

- Within 48 months after the original issuedate of this service bulletin. Within 6,000flight cycles after the original issue date ofthis service bulletin. Check the rig of the MCDand do the latch mechanism adjustment test in accordance with Step 5.d. AND Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 5.d.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 21 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition

- Before further flight. Replace cracked or gouged cam latch(es)and latch pin(s) in accordance with Step 6.a. Condition 5: If the detailed, HFEC or magnetic particle inspections specified in the Actions of Conditions 1 thru4 reveal any of the following: AND Do a detailed inspectionof mating part(s) and immediately adjacent cam latch(es) and latch pin(s) for any cracks, or any gouges in critical areas in accordance with Step 6.b.Do all applicable corrective actions as described in Condition 5. 1. Cracked or gouged cam latch(es) in critical areas. 2. Cracked or gouged latch pin(s) in critical areas. AND Unless replaced with new or reworked parts,do aHFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance withStep 6.c. Do all applicable corrective actions as described in Condition 5. (b) AND Check the rig of the MCDand do the latch mechanism adjustment test in accordance with Step 6.d. AND Replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with Step 6.d. (a) All Table 1 repeat inspections are terminated when the rig of the MCD has been checked in accordance with Paragraph 3.B., Work Instructions. Refer to Table 2 for post-rig check inspection requirements. (b) A reworked cam latch is defined as a cam latch that has been reworked within limits of CMM 52-36-61 and/or a Boeing ODA approved repair via FAA Form 8100-9 and has been HFEC or magnetic particle inspected, and has no crack(s) or gouge(s) in critical area(s).

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 22 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 1:Initial and Repetitive Inspections of the Cam Latches, Latch Pins and Latch Pin Cross Bolts for the Main Cargo Door (Pre-Rig Check) Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs First) Action Condition (c) Discrepancy is defined as: Any broken, cracked, missing or gouged cam latches or latch pins, broken or missing latch pin cross bolts, latch pin extension less than 0.89 inches or greater than 0.91 inches, or cam latch lip deformation.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 23 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 2: Repetitive Inspection Requirements for Airplanes that have accomplished All Table 1 Requirements, Including Rigging of the Main Cargo Door in accordance with the Original Issue or Revision 1 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance Time Action Condition 375 flight cycles. Within 375 flight cycles after the rig of the MCD was checked.Do a general visual inspection for any broken or missing cam latch(es), latch pin(s) and latch pincross bolt(s) in accordance with Step 7.a.(1)All Airplanes that have accomplished all Table 1 requirements,including rigging of the main cargo door in accordance with the original issue or revision 1 of this service bulletin and no rigging adjustment of any latch pin or any latch pin fitting was required. 3,000 flight cycles. If latch pin flight cycles are known: Before 20,000 total latch pin flight cycles. Do a detailed inspection of the latch pins for any cracks, or any gouges incritical areas in accordance with Step 7.a.(2) 3,000 flight cycles. If latch pin flight cycles are un- known: AND During previous pre-rigcheck inspection, no discrepancy was found. (b) Within 3,000 flight cycles after the rig of the MCD was checked. 3,000 flight cycles. If cam latch flight cycles areknown and cam latch is not a reworked part: (a) Do a detailed inspection of the cam latches for any cracks, or any gouges incritical areas in accordance with Step 7.a.(2) Before 20,000 total cam latch flight cycles. 3,000 flight cycles. If cam latch flight cycles are un-known or if cam latch is a reworked part: (a) Within 3,000 flight cycles after the rig of the MCD was checked. 6,000 flight cycles. If cam latch flight cycles areknown and cam latch is not a reworked part: (a) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 7.a.(3) Before 20,000 total cam latch flight cycles. 6,000 flight cycles. If cam latch flight cycles are un-known or if cam latch is a reworked part: (a) Within 6,000 flight cycles after the rig of the MCD was checked.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 24 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTable 2: Repetitive Inspection Requirements for Airplanes that have accomplished All Table 1 Requirements, Including Rigging of the Main Cargo Door in accordance with the Original Issue or Revision 1 of this Service Bulletin Repeat Interval (Not to Exceed) Compliance Time Action Condition 375 flight cycles. Within 375 flight cycles after the rig of the MCD was checked.Do a general visual inspection for any broken or missing cam latch(es), latch pin(s) and latch pincross bolt(s) in accordance with Step 8.a.(1)All Airplanes that have accomplished all Table 1 requirements, including rigging of the main cargo door in accordance with the original issue or revision 1 of this service bulletin and rigging adjustment of any latch pin or any latch pin fitting was required. 3,000 flight cycles. Within 3,000 flight cycles after the rig of the MCD was checked. Do a detailed inspection of the cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with Step 8.a.(2) OR During previous pre-rigcheck inspection, any discrepancy was found. (b) 6,000 flight cycles. Within 6,000 flight cycles after the rig of the MCD was checked. Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with Step 8.a.(3)

- Before further flight. Contact The BoeingCompany for repair instructions and do the repair. Any discrepancy found.

(a) A reworked cam latch is defined as a cam latch that has been reworked within limits of CMM 52-36-61 and/or a Boeing ODA approved repair via FAA Form 8100-9 and has been HFEC or magnetic particle inspected, and has no crack(s) or gouge(s) in critical area(s). (b) Discrepancy is defined as: Any broken, cracked, missing or gouged cam latches or latch pins, broken or missing latch pin cross bolts, latch pin extension less than 0.89 inches or greater than 0.91 inches, or cam latch lip deformation. 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 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 25 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTG. Manpower The table below shows an estimate of the task hours necessary to do the inspections and modifications for each airplane. 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. Elapsed Hours Task Hours Number of Persons Task 0.25 0.25 1 Open Access 1.60 1.60 1 FIGURE 1 0.50 0.50 1 FIGURE 2 0.50 0.50 1 FIGURE 3 1.00 (h) 1.00 (h) 1 FIGURE 4 1.00 1.00 1 FIGURE 5 0.50 (a) (f) (i) 0.50 (a) (f) (i) 1 (i) FIGURE 6 0.10 (b) (g) 0.10 (b) (g) 1 FIGURE 7 0.60 (c) 0.60 (c) 1 FIGURE 8 0.10 (d) 0.10 (d) 1 FIGURE 9 20.00 48.00 2-3 FIGURE 10 - FIG- URE 11 0.25 0.25 1 Close Access (e) (e) TOTAL FOR EACH AIRPLANE (a) Estimate is per cam latch requiring replacement. (b) Estimate is per latch pin requiring replacement. (c) Estimate is per cam latch requiring inspection. (d) Estimate is per cam latch.(e) Total time required may vary depending upon conditions found during inspections. (f) Does not include time to match drill cam shaft. (g) Does not include time to match drill latch pin. (h) Does not include NDI inspection time. (i) Cam latch 4 will require 2 hours and a second person to remove.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 26 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTH. Weight and Balance Changes Change in Moment (Pound-Inches) Change in Weight (Pounds) Airplane Negligible Negligible 707-300 Negligible Negligible 707-300B Negligible Negligible 707-300C
I. Electrical Load Data Not applicable. J. References 1. Existing Data: a. Boeing Service Bulletin 707-3477 b. Boeing Service Letter 707-SL-51-029 c. Boeing Service Related Problem (SRP) 707-52-0088 d. Component Maintenance Manual (CMM) 52-36-61 e. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 91-22-04 f. Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM) 2012-NM-132-AD g. Aircraft Maintenance Manual (AMM) 707 AMM 52-11-0 h. Standard Overhaul Practices Manual (SOPM) 20-20-01 i. 707, 720 Non-Destructive Testing (NDT) Manual Part 6, 51-00-00 j. 707 Fleet Team Digest (FTD) 52-09001 k. 707-300/400 Structural Repair Manual (SRM) 51-00-06 2. Data Supplied with this Service Bulletin:
None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
Title Drawing Number DOOR INSTALLATION - MAIN CARGO 65-25326 LATCH MECHANISM INSTALLATION - MAIN CARGO DOOR 65-25339

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 27 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTTitle Drawing Number SILL INSTL - LOWER, MAIN CARGO DOOR 65-25343 LATCH PIN FITTING - ASSY 65-25771 CAM - LATCH MECHANISM CARGO DOOR 69-23438 BODY INSTALLATION - SECTION 43 50-2543 The table above lists applicable drawings used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. K. Publications Affected
1. Publications Chapter-Section Publication 52-11 707 Aircraft Maintenance Manual 52-03 707 Illustrated Parts Catalog 52-36-61 Component Maintenance 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. Repairs accomplished on cam latch(es) in accordance with CMM 52-36-61 are structurally acceptable as Category A repairs as defined as: "A permanent repair for which the inspections given in the Maintenance Planning Data (MPD) document, are sufficient and no other actions are necessary", therefore no supplemental inspections to the mandated damage tolerance inspections contained in Paragraph 1.E., Compliance, Table 2, of this service bulletin, are required. 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 28 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT2. MATERIAL INFORMATION A. Material - Price and Availability The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each Airplane . As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin does not show the Boeing price and supply data. B. Industry Support Information Boeing warranty remedies are not available for the inspections and modifications given in this service bulletin. C. Parts Necessary for Each Airplane 1. Kits/Parts
None. 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.
Notes Name QTY Part Number / Specification (a) (b) BOLT, HEX HEAD, 160 KSI MIN TENSILE, LONG THREAD, A286,NON LOCKING 8 BACB30LM3-24 OR BACB30LM3-22 Parts are only needed if existing part cannot be reworked. (c) (g) Cam Latch 1

- 69-23438-2 Cam Latch 2

- 143N8060-1 Cam Latch 3

- 143N8027-2 Cam Latch 4

- 69-23439-3 Cam Latch 5

- 69-23439-4 Cam Latch 6

- 143N8027-1 Cam Latch 7

- 143N8060-2 Cam Latch 8

- 69-23438-1 Latch Pin

- 6-83137-2 (d) Corrosion Inhibiting Compound 5 oz. BMS 3-27 (d) Pressure and Environmental Sealant 5 oz. BMS 5-95, TYPE I, CLASS B 1/2 (e) Flexbar ReproRubber Quicksetting Putty or equivalent 8 oz.

- (f) Rod, 3/16 diameter, 2 inches long 1

-

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 29 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTNotes Name QTY Part Number / Specification (a) Refer to 707 Structural Repair Manual Chapter 51 for alternate fasteners. (b) BACB30LM3-24 is used if optional 143N8157-2 Clip Assembly is installed. (c) Drill attachment holes to the new latch cam to match with the existing bell crank assembly to ensure proper installation and clocking. (d) Refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier data. (e) Available from Flexbar Machine Corp. (2R260), 250 Gibbs Road, Islandia, NY 11749,USA. (f) Used for aligning the rigging pin slot with the cross bolt hole in accordance with APPENDIX A. (g) Part numbers and quantities necessary are dependent on inspection findings.
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 Boeing can supply the tool(s) shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The tool(s) are subject to the terms and conditions of the Boeing standard purchase order acknowledgement. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin number and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 30 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTREFER 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
Purchase Data: Unit Price as of the Revision 1date of this Service Bulletin (US Dollars) Name Tool Kit Number

8,821.00 Pin Set - Rigging, Main Deck, Main Cargo Door B52029-1

Rental Data: Daily Price as of the Revision 1date of this service bulletin (US Dollars) Name Tool Kit Number

180.00 Pin Set - Rigging, Main Deck, Main Cargo Door B52029-1

F. Special Tooling Necessary to do this Service Bulletin To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability. Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be necessary. Examine operator tool supply to make sure all necessary tools are available.
Name Tool Kit Number Pin Set - Rigging, Main Deck, Main Cargo Door B52029-1

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 31 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTExport Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 32 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT

BLANK PAGE3. 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.

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. Clearance between fasteners and surrounding structures or mechanisms may be minimal by design at some locations. Use caution when adjusting grip length of fasteners and make sure no interference conditions exist after installation. Interference between moving parts may be difficult to detect. Complete full cycle of mechanisms to ensure no interference conditions exist. 7. A Detailed Inspection is defined as: An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be necessary. Surface cleaning and elaborate procedures may be required.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 33 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT8. A General Visual Inspection is defined as: A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. 9. 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. 10. Boeing Service Letter 707-SL-51-029 Damage Reporting and Repair Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided. 11. Refer to APPENDIX A for the Latch Mechanism Adjustment Test. 12. 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. 13. 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. 14. 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. 15. 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. 16. 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. 17. Damage found on cam latch(es) within the reworkable limits of CMM 52-36-61 can be reworked in accordance with CMM 52-36-61. 18. A reworked cam latch is defined as a cam latch that has been reworked within the limits of CMM 52-36-61 and/or a Boeing ODA approved repair via FAA Form 8100-9 and has been HFEC or magnetic particle inspected, and has no crack(s) or gouge(s) in critical area(s).

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 34 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT19. Discrepancy is defined as: Any broken, cracked, missing or gouged cam latches or latch pins, broken or missing latch pin cross bolts, latch pin extension less than 0.89 inches or greater than 0.91 inches, or cam latch lip deformation. 20. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS are in Paragraph 1.E., Compliance. B. WORK INSTRUCTIONS 1. Initial (Pre-Rig Check) Inspections. a. Get access to the Main Cargo Door (MCD). b. Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts and for any missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. c. Torque the cross bolts in the latch pins in accordance with FIGURE 2. d. Measure the extension of the latch pins in accordance with FIGURE 3 e. Do a general visual inspection of all cam latches for lip deformation in accordance with FIGURE 1. 2. Condition 1: One or more of the following is found: – Broken or missing cam latch(es) – Broken or missing latch pin(s) – Broken or missing latch pin cross bolt(s) a. Replace broken and missing cam latch(es) in accordance with FIGURE 6, replace broken and missing latch pin(s) in accordance with FIGURE 7 and replace broken and missing latch pin cross bolt(s) in accordance with FIGURE 5. b. Do a detailed inspection of mating part(s) and immediately adjacent cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with FIGURE 8. Do all applicable corrective actions as described in Condition 5. c. Unless replaced with new or reworked parts, do a High Frequency Eddy Current (HFEC) or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. d. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 3. Condition 2: The latch pin extension is less than 0.89 inches or greater than 0.91 inches: a. Replace the discrepant latch pin in accordance with FIGURE 7.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 35 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTb. Do a detailed inspection of the mating cam latch for any cracks, or gouges in critical areas in accordance with FIGURE 8. Do all applicable corrective actions as described in Condition 5. c. Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts and for any missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. Do all applicable corrective actions as described in Condition 1. d. Do a detailed inspection of all the latch pins and mating cam latches for any cracks, or any gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. e. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. f. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5.
NOTE: Rigging for the latch pin will require it to be installed properly with an extension of 0.90 +/- 0.01 inches. A latch pin with an original extension between 0.84 to 0.94 inches, with no cracks or gouges in critical areas and no other discrepancies may be re-used by clocking the latch pin 90 degrees +/- 10 degrees from original position and match drilling a new cross bolt hole that provides the correct latch pin extension. Fill old cross bolt hole in pin with BMS 5-95 sealant and install pin with BMS 3-27 corrosion inhibiting compound. 4. Condition 3: If a cam latch is found with lip deformation. a. Do a detailed inspection of the discrepant cam latch and mating latch pin for any cracks, or gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. b. Do a general visual inspection for any broken cam latches, latch pins and latch pin cross bolts and for any missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. Do all applicable corrective actions as described in Condition 1. c. Do a detailed inspection of all cam latches and mating latch pins for any cracks, or any gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. d. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. e. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 5. Condition 4:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 36 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTNo discrepancies found: a. Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. Do all applicable corrective actions as described in Condition 1. b. Do a detailed inspection of the cam latches and latch pins for any cracks, or any gouges in critical areas in accordance with FIGURE 1. Do all applicable corrective actions as described in Condition 5. c. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. d. Check the rig of the MCD in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 6. Condition 5: If the detailed, HFEC or magnetic particle inspections in Conditions 1 thru 4 reveal any of the following: – Cracked or gouged cam latch(es) in critical areas. – Cracked or gouged latch pin(s) in critical areas. a. Replace cracked or gouged cam latch(es) in accordance with FIGURE 6, replace cracked or gouged latch pin(s) in accordance with FIGURE 7. b. Do a detailed inspection of mating part(s) and immediately adjacent cam latches and latch pins for any cracks or any gouges in critical areas in accordance with FIGURE 8. Do all applicable corrective actions as described in Condition 5. c. Unless replaced with new or reworked parts, do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. Do all applicable corrective actions as described in Condition 5. d. Check the rig of the Main Cargo Door in accordance with FIGURE 10 and FIGURE 11, and do the latch mechanism adjustment test in accordance with APPENDIX A, and replace all alloy steel cross bolts through the latch pins with CRES cross bolts in accordance with FIGURE 5. 7. Post Rig Check Repetitive Inspections. a. All Airplanes that have accomplished all Table 1 requirements identified in Paragraph 1.E., Compliance, including rigging of the MCD in accordance with the original issue or Revision 1 of this service bulletin and no rigging adjustment of any latch pin or any latch pin fitting was required, and during previous pre-rig check inspections there were no discrepancies found: (1) Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin Cross Bolt in accordance with FIGURE 9.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 37 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT(2) Do a detailed inspection of the cam latches and latch pins for any cracks or any gouges in critical areas in accordance with FIGURE 1. (3) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. (4) If any discrepancy is found, contact The Boeing Company for repair instructions and do the repair. 8. Post Rig Check Repetitive Inspections. a. All Airplanes that have accomplished all Table 1 requirements identified in Paragraph 1.E., Compliance, including rigging of the MCD in accordance with the original issue or Revision 1 of this service bulletin and rigging adjustment of any latch pin or any latch pin fitting was required, or during previous pre-rig check inspections there were any discrepancies found. (1) Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin cross bolts in accordance with FIGURE 9. (2) Do a detailed inspection of the cam latches and latch pins for any cracks or any gouges in critical areas in accordance with FIGURE 1. (3) Do a HFEC or magnetic particle inspection of cam latch 1 and cam latch 2 for any cracks in critical areas in accordance with FIGURE 4. (4) If any discrepancy is found, contact The Boeing Company for repair instructions and do the repair. 9. Put the airplane back to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1: September 16, 2015 38 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION (SHEET 1 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 39 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION (SHEET 2 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 40 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a) (b) 1 69-23438-2 Cam Latch 1 Inspect 1 (a) (b) 1 143N8060-1 Cam Latch 2 Inspect 2 (a) (b) 1 143N8027-2 Cam Latch 3 Inspect 3 (a) (b) 1 69-23439-3 Cam Latch 4 Inspect 4 (a) (b) 1 69-23439-4 Cam Latch 5 Inspect 5 (a) (b) 1 143N8027-1 Cam Latch 6 Inspect 6 (a) (b) 1 143N8060-2 Cam Latch 7 Inspect 7 (a) (b) 1 69-23438-1 Cam Latch 8 Inspect 8 (a) 8 6-83137-2 Latch Pin Inspect 9 (a) Do Detailed inspection for cracks or gouges in critical areas. (b) Do a general visual inspection for lip deformation.

FIGURE 1: MAIN CARGO DOOR - CAM LATCHES AND LATCH PINS INSPECTION (SHEET 3 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 41 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT (SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 42 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a) 8

- Cross Bolt Torque 1 (a) Make sure the latch pin cross bolt is capable of reaching a 15 pound-inch, +/- 1 pound-inch, torque from the head side of the bolt and also the nut side if no nutplate is used. The 15 pound-inch, +/- 1 pound-inch, torque value is approximately one-half of the installation torque and is used to give an indication of a broken cross bolt.

FIGURE 2: MAIN CARGO DOOR - LATCH PIN CROSS BOLT TORQUE MEASUREMENT (SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 43 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT (SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 44 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step Make sure the latch pin extends out 0.90 inch +/- 0.01 inch from the wear plate. 8 6-83137-2 Latch Pin Measure 1

FIGURE 3: MAIN CARGO DOOR - LATCH PIN EXTENSION MEASUREMENT (SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 45 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION (SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 46 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step

- 1 69-23438-2 Cam Latch 1 Remove / Keep 1

- 1 143N8060-1 Cam Latch 2 Remove / Keep 2 Do a HFEC inspection of cam latch 1for cracks in accordance with 707, 720 NDT Manual Part 6, 51-00-00, Figure 13 or Figure 24 (a) (b) (c) 1 69-23438-2 Cam Latch 1 Inspect 3

Do a HFEC inspection of cam latch 2for cracks in accordance with 707, 720 NDT Manual Part 6, 51-00-00, Figure 13 or Figure 24 (a) (b) (c) 1 143N8060-1 Cam Latch 2 Inspect

- 1 69-23438-2 Cam Latch 1 Install (Kept) 4

- 1 143N8060-1 Cam Latch 2 Install (Kept) 5 (a) Use a 0.080 inch diameter or smaller HFEC probe. Set the HFEC instrument to operate between 50 KHzand 75 KHz. If HFEC method indicates a crack, confirm a crack indication using magnetic particle inspection. Refer to SOPM 20-20-01 as an accepted procedure. (b) An optional magnetic particle inspection can be used. Refer to SOPM 20-20-01 as an accepted procedure. (c) HFEC crack indications can be confirmed using the magnetic particle inspection. If crack indications are found with HFEC and could not be confirmed with magnetic particle inspection, the HFEC crack indication is a non relevant indication due to chrome cracking.

FIGURE 4: MAIN CARGO DOOR - CAM LATCH 1 AND CAM LATCH 2 INSPECTION (SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 47 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT (SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 48 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step

- 8 NAS1303-22 (NAS1303-30 or NAS1103-29 or NAS1103-30 or NAS1303-29 optional) Latch Pin Cross Bolt Remove 1

Install with BMS 3-27 corrosion inhibiting material. 8 BACB30LM3-22(BACB30LM3-24 optional) Latch Pin Cross Bolt Install (New) 2

FIGURE 5: MAIN CARGO DOOR - LATCH PIN CROSS BOLT REPLACEMENT (SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 49 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT (SHEET 1 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 50 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a) 1 69-23438-2 Cam Latch 1 Remove 1 (a) 1 143N8060-1 Cam Latch 2 Remove (a) 1 143N8027-2 Cam Latch 3 Remove (a) Gusset must beremoved to allow removal of cam latch number 4. 1 69-23439-3 Cam Latch 4 Remove

(a) 1 69-23439-4 Cam Latch 5 Remove (a) 1 143N8027-1 Cam Latch 6 Remove (a) 1 143N8060-2 Cam Latch 7 Remove (a) 1 69-23438-1 Cam Latch 8 Remove

FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT (SHEET 2 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 51 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTMore Data Qty Identification Name Task Step (a) (b) (d) 1 69-23438-2 Cam Latch 1 Install (New) 2 (a) (b) (c) (d) 1 143N8060-1 Cam Latch 2 Install (New) (a) (b) (d) 1 143N8027-2 Cam Latch 3 Install (New) (a) (b) (d) Gusset must be removed to allow installation of cam latch number 4. 1 69-23439-3 Cam Latch 4 Install (New)

(a) (b) (d) 1 69-23439-4 Cam Latch 5 Install (New) (a) (b) (d) 1 143N8027-1 Cam Latch 6 Install (New) (a) (b) (c) (d) 1 143N8060-2 Cam Latch 7 Install (New) (a) (b) (d) 1 69-23438-1 Cam Latch 8 Install (New) (a) Part numbers and quantities necessary are based on inspection findings.(b) Use the original removed cam latch as a pattern/template to locate new cross bolt holes. Match hole angularity from existing cam latch. (c) Cam latch number 2 and cam latch number 7 only have two cross bolt holes. (d) It is acceptable to install a reworked Cam Latch with the same part number instead of a new part.

FIGURE 6: MAIN CARGO DOOR - CAM LATCH REPLACEMENT (SHEET 3 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 52 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT (SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 53 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step

- 6-83137-2 Latch Pin Remove 1 Install latch pin wetwith BMS 3-27 corrosion inhibiting material on faying surfaces. Make sure the latch pin extends out 0.90 inch +/-0.01 inch from the wear plate. - 6-83137-2 Latch Pin Install (New) 2

FIGURE 7: MAIN CARGO DOOR - LATCH PIN REPLACEMENT (SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 54 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION (SHEET 1 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 55 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION (SHEET 2 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 56 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a) (b) 1 69-23438-2 Cam Latch 1 Remove / Keep 1 (a) (b) 1 143N8060-1 Cam Latch 2 Remove / Keep (a) (b) 1 143N8027-2 Cam Latch 3 Remove / Keep (a) (b) (c) 1 69-23439-3 Cam Latch 4 Remove / Keep (a) (b) 1 69-23439-4 Cam Latch 5 Remove / Keep (a) (b) 1 143N8027-1 Cam Latch 6 Remove / Keep (a) (b) 1 143N8060-2 Cam Latch 7 Remove / Keep (a) (b) 1 69-23438-1 Cam Latch 8 Remove / Keep Detailed inspection of the cam latch for cracks or gouges in critical areas. (d) - - Cam Latch Inspect 2

(a) (b) (e) 1 69-23438-2 Cam Latch 1 Install (Kept) 3 (a) (b) (e) 1 143N8060-1 Cam Latch 2 Install (Kept) (a) (b) (e) 1 143N8027-2 Cam Latch 3 Install (Kept) (a) (b) (e) 1 69-23439-3 Cam Latch 4 Install (Kept) (a) (b) (e) 1 69-23439-4 Cam Latch 5 Install (Kept) (a) (b) (e) 1 143N8027-1 Cam Latch 6 Install (Kept) (a) (b) (e) 1 143N8060-2 Cam Latch 7 Install (Kept) (a) (b) (e) 1 69-23438-1 Cam Latch 8 Install (Kept) Detailed inspection of the latch pin for cracks or gouges in critical areas. 8 6-83137-2 Latch Pin Inspect 4

(a) It is important to identify the Cam Latch part locations to make sure the parts are installed in correct locations. Cam latches installed incorrectly may seriously compromise proper door operation. (b) Part numbers and quantities necessary are based on inspection findings. (c) Gusset must be removed to allow removal of cam latch number 4. (d) Only inspect removed cam latch(es). (e) Do not install kept cam latch if cracked or gouged in critical areas.

FIGURE 8: MAIN CARGO DOOR - CAM LATCH REMOVAL AND INSPECTION (SHEET 3 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 57 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 9: MAIN CARGO DOOR - CAM LATCHES, LATCH PINS AND LATCH PIN CROSS BOLTS INSPECTION (SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 58 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step General visual inspection of the cam latch. (a) 1 69-23438-2 Cam Latch 1 Inspect 1

General visual inspection of the cam latch. (a) 1 143N8060-1 Cam Latch 2 Inspect

General visual inspection of the cam latch. (a) 1 143N8027-2 Cam Latch 3 Inspect

General visual inspection of the cam latch. (a) 1 69-23439-3 Cam Latch 4 Inspect

General visual inspection of the cam latch. (a) 1 69-23439-4 Cam Latch 5 Inspect

General visual inspection of the cam latch. (a) 1 143N8027-1 Cam Latch 6 Inspect

General visual inspection of the cam latch. (a) 1 143N8060-2 Cam Latch 7 Inspect

General visual inspection of the cam latch. (a) 1 69-23438-1 Cam Latch 8 Inspect

General visual inspection of the latch pins. (a) 8 6-83137-2 Latch Pin Inspect 2

General visual inspection of the latch pin cross bolt. (a) 8

- Cross Bolt Inspect 3

(a) Do a general visual inspection for any broken or missing cam latches, latch pins and latch pin cross bolts.

FIGURE 9: MAIN CARGO DOOR - CAM LATCHES, LATCH PINS AND LATCH PIN CROSS BOLTS INSPECTION (SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 59 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING (SHEET 1 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 60 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING (SHEET 2 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 61 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a) (b) 8

- Cam Latch Measure 1 (a) (b) 8 6-83137-2 Latch Pin Measure (c) 8

- Latch Pin Fitting Measure (a) During rigging procedure the latch pin is not to contact the cam latch in any direction. (b) Wrap a single layer of 0.002 inch thick shim stock around latch pins 1 and 8. Use thin tape to keep shim in place. With latch pins 1 and 8 engaging their respective cam latches, and with latch pins 2 through 7 not contacting their respective cam latches in any direction, adjust if required, latch pin fittings 2 through 7 such that latch pins 2 through 7 axial centerlines and their respective cam latch axial centerlines are within the tolerance shown. (c) Adjust latch pin fittings by moving fitting on serrations and by adjusting shim thickness. On the two forward and two aft cam latches the Latch Pin Fitting/Cam Latch gap is 0.14 +/- 0.01 inch. On the four center cam latches the Latch Pin Fitting/Cam Latch gap is 0.08 +/- 0.01 inch. 0.20 inch shim thickness maximum.

FIGURE 10: MAIN CARGO DOOR - CAM LATCH AND LATCH PIN RIGGING (SHEET 3 OF 3)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 62 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTFIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT (SHEET 1 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 63 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTThe 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 this figure.
More Data Qty Identification Name Task Step (a)

- - Main Cargo Door Measure 1 (a) Hold scale 90 degrees to door edge. Make sure the MCD lower edge and lower corner flushness are within the tolerance shown.

FIGURE 11: MAIN CARGO DOOR - MAIN CARGO DOOR EDGE FLUSHNESS MEASUREMENT (SHEET 2 OF 2)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 64 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT1. Prepare to Adjust the Latch Mechanisms (Appendix A Figure A1.1) WARNING: MAKE SURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE CARGO DOOR PATH BEFORE YOU OPERATE THE CARGO DOOR CONTROL SWITCH. THE CARGO DOOR CAN CONTINUE TO MOVE AFTER YOU RELEASE THE SWITCH. THIS CAN CAUSE INJURIES TO PERSONNEL AND DAMAGE TO EQUIPMENT. a. Electrically close the door to the "latched-and-locked" position. b. Use tape to mark the approximate location of the cam latch head, locations 1 through 8, on the external side of the door. c. Using a tape measurer, measure the external cargo door flushness between the sill plate and the door at cam latch heads 1 through 8 (Appendix Figure A3). d. Record the flushness measurements at cam latch head locations 1 through 8 (Appendix A Figure A4.1). e. Open the main cargo door to approximately 1/4 of the fully open position. f. Clean the lower sill area around the latch pins and latch pin fittings with a cotton cloth. g. Clean the head and throat of the cam latches with a cotton cloth. h. Remove the cross bolt and clip or the cross bolt and nut from the latch pin fitting at sill locations 2 through 7. i. Remove the latch pins at sill fitting locations 2 through 7 from the latch pin fittings (Appendix A Figure A1.3). j. Record the latch pin location to the mating latch pin fitting. k. Clean the latch pin holes in the latch pin fittings. l. Wrap a 0.002 in. (0.051 mm) shim fully around the latch pins at sill fitting locations 1 and 8, making a full circle. (1) Make sure that you do not overlap the shims. (2) Use thin tape to hold the ends of the 0.002 in. (0.051 mm) shim. (3) Turn the shim until the splice points to the inboard side of the latch pin. m. Electrically close the door to the "latched-and-locked" position. n. Make sure that the 0.002 in. (0.051 mm) shims are on the pins. o. Record the external flushness values for cam latch head locations 1 through 8 (Appendix A Figure A4.1).

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 1 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 65 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTNOTE: Flushness values show if it is necessary to adjust fittings 1 and 8. You will not rig the door with these flushness values. NOTE: Have the same person measure the flushness as measured earlier in the task. p. Do these steps for latch fittings 1 and 8 if the lower edge flushness values are more than the tolerances (Appendix Figure A3). (1) Remove latch fitting fillet seals. (2) Remove the cap seals. (3) Remove the leveling compound. (4) Record the location of the latch pin fitting on the mating serrated plate. (5) Measure shim thickness to make sure that the latch pin fitting 1 and 8 adjustments can move the door into the necessary flushness (Appendix Figure A1.3). NOTE: If you remove 0.10 in. (2.54 mm) of the shim thickness, the door will move approximately 0.07 in. (1.78 mm) in the inboard direction. (6) Do these steps if the door is more than the flushness tolerance in this configuration: (a) Remove only one of the setscrew lock wires. (b) Loosen the setscrew to loosen the fitting. (c) You may need to use a 1/4 inch 8 point socket. (d) Remove the fitting. (e) Record the location of the fasteners. (f) Record the corresponding latch pin fitting location number on the serrated plate. (g) Carefully clean the serrations and all mating surfaces. Be careful to not remove the recorded location numbers and location marks. (h) Adjust the latch pin shim thickness. (i) If you move the latch pin fitting inboard, then increase the clearance between the stop pin and the stop pad. (j) Move the latch fitting up one serration if you removed more than 0.071 in. (1.803 mm) shim thickness. (k) Move the latch fitting down one serration if you added more than 0.071 in. (1.803 mm) shim thickness.

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 2 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 66 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT(l) If necessary, change the length of the latch pin fitting fasteners for adjusted shim thickness. (m) Install the latch pin fitting without the fillet seal. (n) Make sure that the set screw is seated and tight. (o) Install the three 0.5 in. (12.7 mm) bolts into the latch pin fitting with 200 in-lb (23 N m) to 225 in-lb (25 N m) torque. (p) Install the 0.625 in. (15.875 mm) bolt into the latch pin fitting with 800 in-lb (90 N m) to 850 in-lb (96 N m) torque. q. Make sure that the 0.002 in. (0.051 mm) shims are on latch pins 1 and 8. WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO OPEN OR CLOSE THE CARGO DOOR. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR. r. Manually close the door to the "latched and locked" position. s. Make sure that there is forward/aft clearance between the cam latches and the latch pin fittings when the door is closed. t. If there is not forward/aft clearance, then adjust the cam latches and the latch pin fittings (Appendix A Figure A1.1). u. Repeat the steps for the external flushness door measurements until the door is within the flushness requirements (Appendix Figure A3). (1) Use the Interim Flushness Recording Table to record measurements, if more adjustments are necessary (Appendix Figure A4.1). v. Electrically open the main cargo door to approximately 1/8 of the fully open position. w. Make sure that the sequence valve has 0.40 in. (10.16 mm) to 0.50 in. (12.70 mm) clearance (Appendix A Figure A1.2). x. Make sure that the cam latch hook is adjusted to the correct clearance. 2. Latch Mechanism Adjustment Test (Appendix A Figure A4.1 - A4.5) a. Put a piece of cardboard in front of the tooling hole in the cam latch throat. NOTE: The cardboard prevents the rubber compound from entering the tooling holes. The cardboard at the base of the cam latch will not impact the measurement. (1) Mark the back of the cardboard with the corresponding latch numbers 2 through 7. (2) Make sure that the cardboard is near flush with the rear of the cam latch throat.

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 3 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 67 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTb. At the latch pin fitting locations 2, 3, 5, 6, and 7, use the rigging pin set, B52029-1 and install the long rig pins. (1) Make sure that the end face of the smaller diameter is flush with the bearing plate on the mating pin fitting. (2) Align the long slot in the rigging pin with the inboard cross bolt hole on the latch pin fitting. (3) Acceptable to use a rod (3/16 Inch Diameter, 2 Inch Length), to align the rigging pin slot with the cross bolt hole. c. At latch pin fitting location 4, using the rigging pin set, B52029-1, install the short rig pin. CAUTION: MAKE SURE THAT THE END OF THE SMALLER DIAMETER IS FLUSH WITH THE BEARING PLATE ON THE MATING LATCH PIN FITTING. IF IT IS NOT FLUSH, DAMAGE TO THE DOOR CAN OCCUR. (1) Make sure that the end of the smaller diameter is flush with the bearing plate on the mating latch pin fitting. (2) Align the long slot in the rigging pin with the inboard cross bolt hole on the latch pin fitting. (3) You can use a rod (3/16 Inch Diameter, 2 Inch Length), STD-10085, to align the rigging pin slot with the cross bolt hole. d. Prepare door for "power on", but do not close the door. e. Mix a sufficient quantity of Flexbar ReproRubber Quicksetting Putty, to fill each cam throat.
NOTE: In warm weather, you can decrease the catalyst compound by approximately 1/3 to increase the working time. f. Quickly put the Flexbar ReproRubber Quicksetting Putty, G50673 into the cam throats at cam latch locations 2 through 7. NOTE: This has to be done in less than 45 seconds for all cam latches. g. Close the door to the "latched and locked" position before the rubber compound paste sets. h. Quickly move the pins at latch pin fitting locations 2 through 7 into the cam throat.
NOTE: You must close the door and move the pins in less than 1 minute for all cam latch pairs. (1) Make sure that the larger diameter touches the cam. i. Let the Flexbar ReproRubber Quicksetting Putty, G50673 set for 10 minutes at 72 degree F (22 degrees C). j. If possible, retract the rigging pins until the pins are flush with the bearing plate in the pin fitting.

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 4 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 68 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTk. Carefully open the main cargo door to approximately 1/4 of the fully open position.
NOTE: The rubber compound can possibly fall out of the cam when the door moves. (1) Look for the rubber compound molds. The molds can fall while the door opens. l. Carefully remove the Flexbar ReproRubber Quicksetting Putty, G50673 in each of the cams at latch pin fitting locations 2 through 7. m. Record the cam latch location onto the rubber compound, near the closed end of the rubber mold. n. Cut the Flexbar ReproRubber Quicksetting Putty, G50673 approximately 0.5 in. (12.7 mm) from the closed end of the rubber compound mold, see Appendix A illustration. (1) Keep the rubber piece with the cross-hair marks. (2) Discard the rubber piece without the cross-hair marks. o. Make extension lines on the cut piece. (1) Align the extension lines with the cross-hair marks in the rubber compound mold. p. Using a tape measure, measure the thickness of the compound at the one line (measurement "A") and in the middle of the two lines (measurement "B"). q. Record measurements "A" and "B" from the rubber compound molds, from latch pin locations 2 though 7, onto the Latch Mechanism Adjustment Worksheet. (1) If measurement "A" is 0.179 in. (4.547 mm) to 0.229 in. (5.817 mm) and if no serration adjustment is necessary, then do not adjust the latch pin fitting shim thickness. (2) If measurement "A" is not 0.179 in. (4.547 mm) to 0.229 in. (5.817 mm) then adjust the latch pin fitting shim thickness by the amount shown on the worksheet. (3) If measurement "A" is 0.179 in. (4.547 mm) to 0.194 in. (4.928 mm) and if a serration adjustment is necessary, then adjust the latch pin fitting shim. (4) If measurement "A" is 0.195 in. (4.953 mm) to 0.213 in. (5.410 mm) and if a serration adjustment is necessary, then do not adjust the latch pin fitting shim thickness. (5) If measurement "A" is 0.214 in. (5.436 mm) to 0.229 in. (5.817 mm) and if a serration adjustment is necessary, then adjust the latch pin fitting shim. (6) If measurement "B" is 0.179 in. (4.547 mm) to 0.229 in. (5.817 mm) then do not adjust the latch pin fitting serrations. r. Calculate shim and serration adjustment values for each cam latch where adjustment is necessary.
s. Record the calculated values.

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 5 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 69 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTt. Calculate the shim thickness adjustment. u. Calculate the number of serrations necessary for adjustment. 3. Latch Mechanism Adjustment a. If necessary, remove the latch fillet seal, cap seal, and leveling compound on latch pin fittings 2 through 7. b. Record the location of the latch pin fitting on the mating serrated plate. c. Record the shim thickness for the latch pin fittings that will be adjusted. d. Remove only one of the setscrews lock wire. e. If it is necessary, loosen the bolts sufficiently to adjust the serrations. f. If it is necessary, remove the bolts to adjust the shims. g. Loosen the setscrew to loosen the fitting. (1) You may need to use a 1/4 inch 8 point socket. h. Remove the fitting. i. Record the location of the fasteners. j. Record the corresponding latch pin fitting location number on the serrated plate. k. Clean the serrations and all mating surfaces. (1) Be careful to not remove the recorded location numbers and location marks. l. Adjust the latch pin shim thickness as calculated on the Latch Mechanism Adjustment "A" Dimension Worksheet (Appendix Figure A4.4). (1) If necessary, change the length of the sill fitting fasteners for adjusted shim thickness. m. Adjust the latch pin serrations as calculated on the Latch Mechanism Adjustment "B" Dimension Worksheet (Appendix Figure A4.5). (1) Make sure that the serrations are correctly engaged. (2) Make sure that the set screw is seated and tight. n. Install the latch fittings without the fillet seal. (1) Install the three 0.5 in. (12.7 mm) bolts into the latch pin fitting with 200 in-lb (23 N m) to 225 in-lb (25 N m) torque.

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 6 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 70 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT(2) Install the 0.625 in. (15.875 mm) bolt into the latch pin fitting with 800 in-lb (90 N m) to 850 in-lb (96 N m) torque. o. Do the Latch Mechanism Adjustment Test again. p. Make sure that the adjustment is 0.179 in. (4.547 mm) to 0.229 in. (5.817 mm) for latches #2 through #7. (1) If latches #2 through #7 are not 0.179 in. (4.547 mm) to 0.229 in. (5.817 mm), do the Latch Pin Adjustment and Latch Mechanism Adjustment Test. (2) Use the Interim Flushness Recording Table to record measurements, if necessary. q. Make sure that the shim thickness is less than 0.20 in. (5.08 mm) at each latch pin fitting location 1 through 8. r. Remove rigging pin set, B52029-1, used in latch pin fitting locations 2 through 7. s. Remove the rod (3/16 Inch Diameter, 2 Inch Length), STD-10085, from the latch pin fitting locations 1 through 8, if you used them. t. Install latch pins for latch pin fitting locations 2 through 7. (1) Install the cross bolt and clip or the cross bolt and nut to the latch pin fitting. (2) Make sure that the pin extends 0.89 - 0.91 in. from the bearing plate on all eight latch pin fittings. u. Remove the 0.002 in. (0.051 mm) shim and tape around the pins at sill fitting locations 1 and 8. WARNING: OBEY THE INSTRUCTIONS IN THE PROCEDURE TO OPEN OR CLOSE THE CARGO DOOR. IF YOU DO NOT OBEY THE INSTRUCTIONS, INJURIES TO PERSONS OR DAMAGE TO EQUIPMENT CAN OCCUR. v. Use the hydraulic hand pump to slowly close the door to the latched-and-locked position. (1) Make sure that the cam latches smoothly engage the latch pins. w. Using a tape measure, measure the external cargo door flushness between the sill plate and the door at latch cam heads 1 through 8. (1) Record the flushness at cam latch head locations 1 through 8 (Appendix A Figure A4.3). (2) Make sure that the lower edge of the cargo door skin is within flushness tolerance (Appendix A Figure A3). (3) Open the main cargo door to approximately 1/2 of the fully open position. (4) Make sure that the stop pins are adjusted correctly (Appendix A Figure A2).

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 7 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 71 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT(5) Make sure that the forward/aft clearance for the latch mechanism is correct (Appendix A FigureA1.1). WARNING: MAKE SURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR OF THE CARGO DOOR PATH BEFORE YOU OPERATE THE CARGO DOOR CONTROL SWITCH. THE CARGO DOOR CAN CONTINUE TO MOVE AFTER YOU RELEASE THE SWITCH. THIS CAN CAUSE INJURIES TO PERSONNEL AND DAMAGE TO EQUIPMENT. (6) Close the door to the "latched-and-locked" position. (7) Monitor the door while it closes for unusual operations. 4. Adjust the Sequence Valve (Appendix A Figure A1.1 - A1.3) a. Close and lock the main cargo door. (1) Using a tape measurer, measure the distance between the sequence valve end cap and the striker plate (View A-A). If the distance is not in the tolerance, do the steps that follow to adjust: (a) Open the main cargo door. (b) Loosen the bolts that attach the sequence valve. (c) Move the sequence valve as necessary to get the dimension shown (View A-A). (d) Tighten the bolts. 5. Adjust the Stop Fittings and Stop Pins (Appendix A Figure A2) a. Close and lock the main cargo door. b. See that the stop pins will touch the stop fittings in the area shown. (1) It is acceptable for the stop pin at the bottom, aft edge of the door to touch the stop pad a maximum of 0.06 in. (1.52 mm) below the target area shown in (Appendix A Figure A2). c. Make sure the clearances at the stop fittings are as shown. d. Install the lockspring in the stop pin. 6. Do an operational test of the main cargo door. Refer to 707 AMM 52-11-0 as an accepted procedure.

APPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 8 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 72 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 9 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 73 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 10 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 74 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 11 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 75 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 12 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 76 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 13 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 77 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 14 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 78 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 15 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 79 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 16 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 80 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 17 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 81 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERTAPPENDIX A: LATCH MECHANISM ADJUSTMENT TEST (SHEET 18 OF 18)
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: February 06, 2012 A3536 Revision 1 September 16, 2015 82 of 82 BOEING SERVICE BULLETIN A3536 ALERT ALERT