Number: 

Date: 

Revision 2: 

ATA System: 

34n 

July 26, 1990 

April 15, 1993 

5211 

Commercial 

Airplane 

Group 

707/720 

Service Bulletin 

Revision Transmittal Sheet 

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

DOOR HINGE FITTING REPLACEMENT 

This revision includes all pages of the service bulletin. 

COMPLIANCE INFORMATION RELATED TO THIS REVISION 

Federal Aviation Administration (FAA) Airworthiness Directive 91-22-04, Amendment 39-8064, is related to 

this service bulletin. 

No more work is necessary on airplanes changed by the initial release or Revision 1 or this service bulletin. 

SUMMARY 

This revision adds Instructions to trim the hinge filling if there is interference between the cam and the hinge 

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

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

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

Effectivity paragraph for changes. 

Vertical lines are put on the left edge of each page, except in Paragraph I.A., Effectivity, to show the location 

of Important changes. 

Pages with a revision number and date, but no vertical lines have no important changes. 

REVISION HISTORY 

Initial Release: 

Revision 1: 

Revision 2: 

July 26, 1990 

June 4, 1992 

April15, 1993 

BOEING COMMERCIAl. AIRPLANE GROUP P 0 BOX 3707 SEA TILE. WASHINGTON 96124-2207 
.BDIIND 

Number: 

Date 

Rev•sion 2. 

ATA System: 

34n 

July 26. 1990 

Apnl 15, 1993 

5211 

Commercial 

Airplane 

Group 

707/720 

Service Bulletin 

Summary 

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

DOOR HINGE FITTING REPLACEMENT 

BACKGROUND 

The main cargo doors on 707 airplanes with main 

cargo doors are almost the same as those on the 

757 Package Freighter airplane. When the 757 

Package Freighter was deslgned, better latch 

cams. and better hinge fillings for the pressure 

rehef doors were designed for the main cargo door. 

Boeing has received several reports of wear of the 

lock stop part of hinge fittings on the pressure relief 

doors on 707 and 727 Cargo and Freighter 

airplanes. Boeing has also received reports of 

wear of the latch cams on the main cargo doors on 

707 and 727 Cargo and Freighter airplanes. Wear 

of the lock stop part of the hinge fillings and of the 

latch cams Is thought to be caused by Incorrect 

operation sequence of the hydraulic system of lhe 

main cargo door. 

This service bulletin shows how to Install the better 

latch cams and hinge fittings on main cargo doors. 

Installation of the better parts will elCtend the service 

life of the door latch system. 

Contmued operation with Installed latch cams and 

h1nge fillings that are worn beyond the hm1ts given 

in this service bulletin is not satisfactory Persons 

cannot make sure that the main cargo door Is 

correctly latched and locked under all possible 

operational conditions if the hinge fillings or the 

latch cams are worn beyond the limits given In this 

service bulletin. 

ACTION 

At the nelCt ·c· check after receipt of this service 

bullefin. or 3000 flight-cycles, Whichever occurs 

sooner, do a visual inspection of the mating 

surfaces on the hinge fitbngs and the latch cams. 

If the hinge fittings are not worn, or are wom wilhin 

the limits gJVen In this service bulletin, eilher install 

new hinge fittings and latch cams, or do the visual 

inspection again at each ·sc· check, or 8000 

ftlght-hours, Whichever occurs sooner. If the hinge 

fitt1ngs are wom beyond the limits g1ven in thiS 

service bulletin, install new hinge filt1ngs and latch 

cams. If the latch cams are worn or damaged, 

install new hinge fittings and latch cams. After the 

new hinge fitllngs and latch cams are Installed as 

shown in this service bulletin, relum to the normal 

Inspection Interval 

Federal Aviation Administration (FAA) 

Airworthiness Directive 91-22-04. Amendment 

39-8064 is related to this service bulletin 

EFFECTIVITY 

All 707 airplanes wrth ma1n cargo doors 

MANPOWER 

Total Man hours - 34 for each airplane 

Elapsed Time - 17 Hours 

MATERIAL INFORMATION 

Boeing Supplied Kll 

See Paragraph I.F for applicable terms and 

conditions 

BOOING COMMERCIAl. AIRPLANE GROVP P 0 SOX 3707 SEAT'Il£ WASHOoiGTON 9612<-2207 Summary Page 1 or 2 
BOEING SERVICE BULLETIN 3477 

/ .j 

-::~' 

' tl/ 

'/ 

~ ~--..._,_ 

~ r# 

.) / 

REPLACE THE HINGE FITTINGS 

PRESSURE 

RELIEF 

DOOR 

FWD 

: ON EACH PRESSURE RELIEF DOOR 

:; (2 PLACES) ~ ~ INBD 

Jul26/90 

REV 2· Apr 15/93 

LATCH 

CAM 

LATCH 

CAM 

BELLCRANK 

REPLACE THE LATCH 

CAMS AND THE BELLCRANK 

(4 PLACES) 

Summary Page 2 of 2 
IIIII NII 

Number: 34n 

Date July 26, 1990 

Revisoon 2 April15, 1993 

ATASystem: 5211 

Commercial 

Airplane 

Group 

707/720 

Service Bulletin 

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

DOOR HINGE FITTING REPLACEMENT 

I. PLANNING INFORMATION 

A. Effectivity 

1. Airplanes Affected 

Refer to the Service Bulletm Index Document 06-164 7. Pan 3 for Airplane Vanable Number. Une 

Number. and Serial Number data 

This change is applocable only to airplanes goven below. 

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER 

AERO URUGUAY (AUG) 

07454 

AERONAVES DEL PERU (REC) 

07606 07618 

AFRICAN AIRLINES (AFX) 

07049 

AHK AIR HONG KONG L TO. (AHK) 

07008 oaon 

AIR CHINA (BEJ) 

09003-09004 09006 

AIR RWANDA (RWO) 

08002 

AIR TCHAD AIRLINES (TCH) 

08402 

ALENIA (AET) 

08329-08330 

AL YEMOA OEM. YEMEN AIRLINES (AL Y) 

08075 08475 

ANGOLA AIRLINES (ANG) 

07079 07081 07102 

Jul26/90 

REV 2: Apr 15193 

07608 07684 08401 

3477 

Page 1 of 37 
BOEING SERVICE BULLETIN 3477 

AVIATION CONSULTANTS (ACT) 

07603 08073 

AVIATION RESEARCH CENTRE (AVR) 

07701-07702 

AVISTAR CYPRUS L TO. (APU) 

08003 

BMAC E-3A FL T. CREW TRAINING (B02) 

07403 07455 

BUFFALO AIRWAYS. INC. (BUF) 

07010 07042 07054 

07807 07816 08152 

CANADIAN DEPT OF DEFENSE (DND) 

08406-08410 

CHALLENGE AIR CARGO (CHA) 

08055 

CHILIAN AIR FORCE (CHF) 

07619 

CHINA SOUTHWEST AIRLINES (XIN) 

09001-09002 09005 

COLOMBIAN AIRFORCE (CLB) 

07109 

COMTRAN INTERNATIONAL INC. (CII) 

07078 

CORDOBA AIR CARGO (CAG) 

07625 

CORSAIR (CRA) 

07614 

DIARO AIR SERVICES (DAR) 

07052 07607 

DOMINICANA AIRLINES (DOM) 

08192 

DUBAJ AIR WING (DAW) 

09251 

E-SYSTEMS (ESM) 

08172 

ECUATORJANA AIRLINES (ECU) 

07045 

Jul26/90 

REV. 2: Apr 15/93 

07802 

07207 

08191 

08309 

07259-07260 07620 

08474 

3477 

2 
BOEING SERVICE BULLETIN 3477 

EGYPT AIR (EGP) 

08201 08203 08205-08207 08210 

EL AL ISRAEL AIRLINES, LTD. (ELA) 

08581-08582 

ETHIOPIAN AIRLINES. CORP. (ETH) 

08129 

EXECUTIVE AVIATION SERVICES (EXS) 

07611 

F.F.T. FRESH FOOD TRADING (FFT) 

07262 

FAST AIR CARRIER (FAC) 

07458 

FLORIDA WEST AIRLINES (PAl) 

07615-07616 

FUERZA AEREA ARGENTINA (AGF) 

06461 06310 06312 06452 

GENERAL ELECTRIC CORP. (GEC) 

02017 

GERMAN REPUBLIC (GRF) 

08221..()6224 

GLOBAL AIR (GLH) 

06051 

GOVERNMENT OF BRAZIL (BRZ) 

07060 08304 08308 06314 

GOVERNMENT OF EGYPT (EGG) 

08209 

GRUMMAN MELBOURNE SYSTEM (GMS) 

07057 07107 07265 

08102 08327 

HEAVYLIFT AIRCRAFT ENGINEERING (HVL) 

07075 

INDONESIAN AIR FORCE (IDO) 

09227 

INTERNATIONAL AIR LEASES (IAL) 

07043 

IRAN AIR (IRN) 

07016 08551-08553 09438 

07806-07609 07612-07613 07817 

Jul 26/90 3477 

REV. 2: Apr 15/93 3 
BOEING SERVICE BULLETIN 3477 

IRAN ISLAMIC AIR FORCE (IAF) 

09101-09107 09161-09167 

IRAQI AIRWAYS (IRQ) 

09221-09223 

ISRAELI AIR FORCE (ISR) 

07406.()7407 08021 08243 

JAMAHIRIYA AIR TRANSPORT (UAA) 

07502-07503 07605 

JET CARGO LIBERIA LTD. (JTC) 

08501 

JET LEASE, INC. (JLI) 

07058 07401 07451 

JUGOSLOVENSKIAEROTRANSPORT(JAn 

07073 

LAOECO (LDE) 

08128 

LAN-CHILE S.A. (LAN) 

07253 07602 07661 

LIBYAN ARAB (LAA) 

07819 09411 

LLOYD AERO BOLIVIANO (LAB) 

07261 

MIDDLE EAST AIRLINES S.A. (MEA) 

08251 

07251.07252 07264 08317-08318 08404-08405 

MILLON AIR, INC. (MLA) 

07257 

NAGANAGANI (NNG) 

08072 

NIGERIA AIRWAYS, LTD. (NIA) 

08319 08333 

NMB SINGAPORE L TO. (NMB) 

08313 

NORTH ATLANTIC TREATY ORGANIZATION(NATO) (NAT) 

07904-07906 

OKADA AIR (OKO) 

08301 

OMEGA AIR (OMG) 

07255 07810 08173 

Jul26/90 

REV. 2· Apr 15/93 

3477 

4 
BOEING SERVICE BULLETIN 3477 

PAKISTAN INTERNATIONAL AIRLINES CORP. (PIA) 

07104 07267 08143-08144 08325 

PAN AVIATION (PAV) 

07053 

PERUVIAN AIR FORCE (PRF) 

07266 

QATAR (OAT) 

08076 09421 

RACE AVIATION CORPORATION (RAC) 

07006 

REPUBLIC OF LIBERIA (LBG) 

05603 

ROYAL AIR MAROC (RAM) 

07622..07623 

ROYAL AUSTRALIAN AIR FORCE (RAA) 

07814-07815 07818 07820 09288 

ROYAL JORDANIAN AIRLINE (RJA) 

08101 

ROYAL MOROCCAN AIR FORCE (MRC) 

09441 

S. R. ACQUISITION CORP. (SRC) 

08127 

SAETA S.A. (SAE) 

07191 

SAFAIR FREIGHTERS (PTY) L TO. (SFA) 

07268 08242 08244 

SAUDI ROYAL FLEET (SRF) 

09281 09290 

SCI BE-AIRLIFT KINSHASA (SAK) 

07907 

SICOTRA AVIATION (SAZ) 

07105 

SKY AIR CARGO (SAC) 

07201 

SKYWAYS INTERNATIONAL, INC (SKL) 

07617 07621 

SOUTHERN AIR TRANSPORT, INC. (STT) 

08306 08471-08472 

Jul26/90 

REV. 2: Apr 15/93 

3477 

5 
BOEING SERVICE BULLETIN 3477 

SPANISH AIR FORCE DATA SUPPORT (SAF) 

07405 09289 

SUDAN (SUD) 

08473 09231-09232 09287 

TAMPA AIRLINES/COLOMBIA (TMP) 

07004 07007 07071 

TAROM ROMANIA(TRM) 

07044 07056 09201-09203 

TRANS ARABIAN AIR TRANSPORT (TRB) 

07047 08054 

TRANS MEDITERRANEAN AIRWAYS (TMA) 

07041 07046 07206 

TRANSBRASIL AIRLINES INC. (TBL) 

07270 08053 08171 

TRATCO LEASING (TRT) 

08004-08005 08008 

USAF - 707 C-137 PROGRAM (U02) 

08271 

USAF- 707 C-18A PROGRAM (U03) 

07211-07213 07215 

USAF- 707 EC·18B PROGRAM (U04) 

07254 07256 07258 

VENEZUELAN AIR FORCE (VEN) 

081 03-081 04 

ZAS AIRLINES (ZAA) 

08007 08074 

IDENTIFICATION BY VARIABLE NUMBER 

02017 05603 06461 

07101-07109 07181 07191 

07451-07458 07501-07504 07601-07626 

07801-07821 07901-07907 08001-08008 

08101-08104 08121-08129 08141-08144 

08201-08210 08221-08224 08241-08244 

08301-08320 08324-08330 08333 

08501-08502 08551-08553 08581-08582 

09201-09204 09221-09223 09227 

09281 09286-09290 09411 

Jul26/90 

REV. 2: Apr 15193 

07077 07801 

07453 08121-08122 08125 

07001-07017 07041-07059 07071-07081 

07201-07215 07251-07271 07401-07407 

07661-07662 07681-07684 07701-07702 

08021 08051-08056 08071-08077 

08151-08153 08171-08173 08191-08192 

08251 08261 08271 

08401-08410 08451-08452 08471-08475 

09001-09006 09101-09107 09161-09167 

09231-09232 09251 09271 

09421 09438 09441 

3477 

6 
BOEING SERVICE BULLETIN 3477 

2. Spares 

Exam1ne your spares supply for the pans Identified in Paragraph II.D., Ex1sllng Pans Accountability. If 

any par1S are found, refer to Paragraph II 0., Existing Par1S Acoountabtilty, for the recommended use. 

Jul26/90 

REV. 2: Apr 15/93 

3477 

7 
BOEING SERVICE BULLETIN 3477 

B. Reason 

The ma1n cargo doors on the 707 aorptanes that have main cargo doors are almost the same as those on 

the 757 Package Freighter a1rplane When the 757 Package Freighter was designed, better latch cams, 

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

latch cams and h1nge fittings lor the 757 Package Freighter were designed to provide better resiStance to 

wear 

This service bulletin shows how to Install the better latch cams and hinge ftHings on the main cargo doors 

on 707 airplanes that have a main cargo door. Installation or the better parts on I he main cargo doors will 

extend the service life or the door latch system. 

Boeing has received several reports or wear or the lock stop part or hinge fitllngs on the pressure relief 

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

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

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

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

system or the main cargo door can occur In seMce due to wear or oomponents of the doo~s hydraulic 

system. or due to a hydraulic system that is not adJUSied correctly. 

Conl!nued operation With installed latch cams and h1nge fittings that are wom beyond the limits g1ven in 

this servtce bulletin Is not satisfactory. Persons cannot make sore that the main cargo door IS CO<Tectly 

locked and latched under all possible operational conditions if the hinge fitt1ngs or the latch cams are 

worn beyond the limits given In this service bulletin 

Revision 2 adds instructions to trim the hinge fitting if there is interference between the cam and the hinge 

fitting when the door is in the closed position. Optional fasteners are added for the Installation of the 

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

Jul26/90 

REV 2: Apr 15/93 

3477 

8 
I 

BOEING SERVICE BULLETIN 3477 

C. Description 

At the next "C" check after receipt of this service bulletin, or 3000 Oight-cyctes. whichever occurs sooner, 

do a visual inspection of the mating surfaces or the hinge fittings (on the pressure relief doors) and the 

latch cams. If the hinge fittings are not wom, or are wom within the limits given In this service bulletin, 

either install the new hinge fittings and latch cams as shown In this service bulletin, or do the visual 

Inspection again at each ·sc" check, or 8000 night-hours, whichever occurs sooner, until the hinge 

fittings and latch cams are replaced as shown In this service bulletin. If the hinge fittings are wom beyond 

the limits given in this service bulletin, Install the new hinge fittings and latch cams as shown in this 

service bulletin. If the latch cams are worn or damaged, install the new hinge fittings and latch cams as 

shown in this service bulletin. After the new hinge fittings and latch cams are installed, return to the 

normal inspection interval. 

If it is necessary to Install the new hinge fittings and latch cams, remove the lining and the Insulation from 

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

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

with new closed-and-latched indicators. Remove the hinge fittings from the pressure relief doors on the 

main cargo door and install new hinge fittings on the pressure relief doors. Do a test of the main cargo 

door to make sure that the door operates, latches, and locks correctly. Do a test of the control system for 

the door to make sure It operates correctly. Do a test of the door warning system tor the main cargo door 

lo make sure It operates correctly. Install the lining and the Insulation on the Inside of the cargo door and 

return the airplane to service. 

Federal Aviation Administration (FAA) Airworthiness Directive 91-22-04. Amendment 39-8064 is related 

to this service bulletin, 

NOTES: 

1. If the main cargo door was deactivated as shown in Service Bulletin 3311 "Main Cargo Door 

Deactivation/Reactivation System Installation•, and no attempt has been made to open the 

cargo door after it was deactivated, then the Inspection shown in this service bulletin can be 

ignored. 

2. If the main cargo door was deactivated as shown in Service Bulletin 3311 "Main Cargo Door 

Deactivation/Reactivation System Installation• then the changes shown in this service bulletin 

can be ignored. 

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

the changes shown in Service Bulletin 3387 "Main Cargo Door Cam Support Fitting Inspection 

and Replacement•. 

D. Approval 

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes shown in 

this service bulletin agree with the applicable Federal Aviatlon Regulatlons (FAR's) and are FAA 

approved. 

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

Bulletin 3477, 'DOORS - MAIN CARGO DOOR • LATCH CAM REPLACEMENT AND PRESSURE 

RELIEF DOOR HINGE FITTING REPLACEMENT". The FAA has approved the inspection and 

replacement procedures in Revision 2 of Service Bulletin 34 77 as an atternatlve to those specified In 

Airworthiness Directive (AD) 91·22·04. Amendment 39-8064. 

Jul26/90 

REV. 2: Apr 15/93 

3477 

9 
BOEING SERVICE BULLETIN 3477 

E. Manpower 

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

The data below shows an eslimale of the man-hours necessary to do this change lor each airplane. This 

estimate is lor direct labor only, done only by an experienced crew. It does not Include lost time such as: 

Ume to adjust to lhe workplace; schedule the work; examine the work; cure materials; make parts: find 

lools or other lost time. Adjust these estimates with operator man-hour data if necessary. 

Number of Elapsed 

Task Persons Man-Hours Time (Hours) 

Open Access 2 2 1 

Change 2 26 13 

Close Access 2 2 1 

Test 2 4 2 

TOTAL FOR EACH AIRPLANE 34 17 

F. Material- Price and Availability 

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

below. Kit availability Is shown In the Reorder Lead Time (ROL T). ROL T is calculated I rom the date 

Boeing gets the purchase order. 

Kit Number 

65-93534-1 (a) 

65-93534-9 

Name 

Top Kit 

Top Klt 

ROLT 

(weeks) 

51 

Unit Price thru 

Oct3, 1993 

$ 15.324.00 

(a) Top Kit 65-93534-1 is held from more sales. Top Kit65-93534-9 

supersedes old Top Kit. 

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

After the Unit Price date, new pnce and ROL T data is applicable. Prices are in United States Dollars. 

Terms: Net 30 days. 

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

bulletin number. 

G. Tooling- Price and Availability 

None 

Jul26/90 

REV. 2: Apr 15/93 

3477 

10 
BOEING SERVICE BULLETIN 3477 

H. Weight and Balance 

None 

I. References 

1. Exisling Data 

a. 707 Maintenance Manual Subjects 52-7-0, 52-11-0, 52-11-43. 52-11-171, 52-11-192 

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

c. Structural Repair Manual Chapter 51 

d. Boeing Service Bulletins: 

o 3311 "Main Cargo Door Deactivation/Reactivation System Installation· 

o 3387 "Main Cargo Door Cam Support Fitting Inspection and Replacement• 

e. Boeing Service Letters: 

o 707 -SL-52-2 "Main Cargo Door Pressure Door Locking Stops• 

o 707 -SL-52-12 "Main Cargo Door Partial Opening in Flight" 

f. FAA Airworthiness Directive 91-22-04, Amendment 39-8064 

2. Data supplied In support or this service bulletin: 

None 

J. Publications Affected 

Publication 

Overhaul Manual 

707 Illustrated Parts Catalog 

Jul26/90 

REV. 2: Apr 15/93 

Chapter-Section 

52-36 

52-30 

3477 

11 
BOEING SERVICE BULLETIN 3477 

II. MATERIAL INFORMATION 

A. Parts Required Per Airplane 

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

NOTE: Top kit is divided Into subkits to make Installation of the parts easier. One 65-93534-9 top kit 

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

by the Operator, are necessary to change each airplane. 

-6 ·5 

1 

1 

1 

1 

1 

1 

2 

Jul26/90 

REV 2: Apr 15/93 

65-93534 - KIT • MAIN CARGO DOOR LATCH CAMS AND LOCK FITIINGS 

-4 -3 ·2 -1 

Quantity 

1 

1 

1 

1 

2 

1 

1 

1 

1 

1 

1 

1 

1 

1 

2 2 2 

Part Number 

65-93534-1 

65-93534-2 

65-93534-3 

65-93534-4 

65-93534-5 

65-93534-6 

143N8027-1 

143N8027-2 

143N8060-1 

143N8060-2 

65-93534-7 

65-93534-8 

69-21969-11 

69-21969-12 

69-23438-1 

69-23438-2 

69-23439-3 

69-23439-4 

69-34974-3 

69-34974-4 

AN960C616L 

AN960PD8L 

Nomenclature 

Top Kit (a) 

Kit, Latch Cams and Bellcrank 

Installation, Body Station 495 

Kit, Latch Cams and Bellcrank 

Installation, Body Station 530 

Kit, Latch Cams and Bellcrank 

Installation, Body Station 570 

Kit. Latch Cams and Bellcrank 

Installation. Body Station 610 

Kit, Pressure Relief Valve Hinge 

installation, Body Stations 510 and 

590 

Cam 

Cam 

Cam 

Cam 

Hinge FiUing 

Hinge Filling 

Bell crank 

Bell crank 

Cam 

Cam 

Cam 

Cam 

Bracket, Lock Indicator 

Bracket, Lock Indicator 

Washer 

Washer 

3477 

12 
BOEING SERVICE BULLETIN 3477 

65-93534- KIT- MAIN CARGO DOOR LATCH CAMS AND LOCK FITTINGS 

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

Quantity Part Number NomenClature 

1 1 BACB30EL5CN19 Boll, Countersink 

3 6 6 3 BACW10P208S Washer 

10 MS204 70B8-14 Rivet 

3 6 6 3 NAS1104-20W Bolt 

1 1 NAS1105-20W Bolt 

1 1 1 1 NAS602-7 Screw 

1 1 1 1 NAS679A08W Nut 

3 6 6 3 NAS679A4W Nut 

2 2 NAS679A5 Nut 

(a) Top Kit 65-93534-1 Is held rrom more sales. Top Kit 65-93534-9 replaces old lop kil 

65-93534 • KIT • MAIN CARGO DOOR LATCH CAMS AND LOCK FITIING 

-6 -13 -12 -11 -10 -9 

Quantity Part Number NomenClature 

- 65-93534-9 Top Kit 

65-93534-10 Kit. Latch Cams and Bellcrank 

Installation. Body Station 495 

1 65-93534-11 Kll, Latch Cams and Bellcrank 

Installation, Body Station 530 

1 65-93534-12 Kit, Latch Cams and Bellcrank 

Installation, Body Station 5 70 

1 65-93534-13 Kit, Latch Cams and Bellcrank 

Installation, Body Station 610 

2 65-93534-6 Kit, Pressure Relief Valve Hinge 

Installation, Body Stations 510 and 

590 

1 65-93534-20 Cam 

1 65-93534-17 Cam 

1 65-93534-14 Cam 

1 65-93534-22 Cam 

1 65-93534-7 Hinge Filtmg 

1 65-93534-8 Hinge Fitting 

1 1 65-93534-18 Bellcrank 

1 1 65-93534-15 Bellcrank 

1 65-93534-23 Cam 

1 65-93534-16 Cam 

Jui26/90 

REV. 2: Apr 15/93 

3477 

13 
BOEING SERVICE BULLETIN 3477 

65-93534 - KIT - MAIN CARGO DOOR LATCH CAMS AND LOCK FITTING 

-6 -13 -12 -11 -10 -9 

Quanlity Part Number Nomenclature 

65-93534-9 Top Kit 

65-93534-19 Cam 

65-93534-21 Cam 

1 1 69-34974-3 Bracket, Lock Indicator 

1 69-34974-4 Bracket, Lock Indicator 

1 1 AN960C616l Washer 

2 2 2 2 AN960PD8L Washer 

1 1 BACB30ELSCN19 Boll. Countersink 

3 6 6 3 BACW10P208S Washer 

10 MS204 70B8-14 Rive! 

3 6 6 3 NAS1104-20W Bolt 

1 1 NAS1105-20W Bolt 

1 1 1 1 NAS602-7 Screw 

1 1 1 1 NAS679A08W Nul 

3 6 6 3 NAS679A4W Nul 

2 2 NAS679A5 Null 

2. Parts and Materials Supplied by lhe Operator: 

Quantity 

50 

5 

7 

2 

16 

20 

20 

14 

16 

As Necessary 

As Necessary 

As Necessary 

2 

Jul26/90 

REV. 2: Apr 15/93 

Part Number or 

Specification 

MS20470D6-7 

BACB30FP6-3 

BACB30FP6-4 

BACB30FP6-5 

BACB30FP8A( ) 

BACB30GY8A( )X 

BACC30K8 

BACC30M6 

BACC30M8 

BMS 1Q-11 , Type I 

BMS 5-95. Class A and Class B 

MIL-G-23827 

Name 

Rivet, Universal Head 

Hi-Lok 

Hi-Lok 

HI-Lok 

Hl-Lok 

Lock bolt 

Collar 

Collar 

Collar 

Primer 

Sealant 

Grease 

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

or 6061-T4 aluminum. See Flgure 2. 

3477 

14 
BOEING SERVICE BULLETIN 3477 

B. Parts Required to Modify Spares 

None 

C. Special Tools and Equipment Required 

The special 1001 shown in Figure 2 of lhis bulletin can be made by the operator. Maintenance and 

overhaul tools can be necessary as given in any manuals that are listed In Paragraph 1.1 •• References. of 

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

Jul26/90 

REV. 2: Apr 15/93 

3477 

15 
BOEING SERVICE BULLETIN 3477 

D. Existing Parts Accountability 

The parts shown below are changed by this service bulletin. Components or sub-assembly parts are 

Indented. The Quantity (Qty) of the Indented part Is the number of parts used on the next higher 

assembly. The quantity or the non-Indented part Is the number of parts changed on the airplane. 

Installed 

Part Number Nomenclature 

65-25339·5 Latch Cam Assembly 

Of: Sta. 600 + 4.65 

(Spares only) 

69-21971-4 Latch Cam 

69-23438-1 Latch Cam 

69-21969·3. -8, 

or -502 

Bellcrank Assembly 

65-25339-6 Latch Cam Assembly 

Of: Sta. 571 .80 

(Spares only) 

69-23439-3 Latch Cam 

69·23439-4 Latch Cam 

69-21969·1. -7, or 

·501 

Bellcrank Assembly 

65-25339-7 Latch Cam Assembly 

Of: Sta. 528.20 

(Spares only) 

69-23439-3 Latch Cam 

69-23439-4 Latch Cam 

69-21969-2, -7, or 

·501 

Bellcrank Assembly 

65-25339-8 Latch Cam Assembly 

or: Sta. 495.35 

(Spares only) 

69-21971-3 Latch Cam 

69-23438-2 Latch Cam 

69-21969-4, ·8,or 

-502 

Bellcrank Assembly 

65-26120-1' ·3, 

or-5 

Hinge, Pressure Valve 

65-26120-2,-4, or 

-6 

Hinge. Pressure Valve 

69-21971·3 or -501 Latch Cam 

69-21971-4 or -502 Latch Cam 

69·23439-1 or -3 Latch Cam 

69-23439·2 or -4 Latch Cam 

Jul26/90 

REV. 2: Apr 15/93 

Oly DC New Part Number 

1 DIS 65-93534-13 

1 DIS 65-93534-22 

1 DIS 65-93534-23 

1 DIS 65-93534-15 

1 DIS 65-93534-12 

1 DIS 65·93534-20 

1 DIS 65-93534-17 

1 DIS 65-93534-18 

1 DIS 65-93534-11 

1 DIS 65-93534-20 

1 DIS 65-93534-17 

1 DIS 65-93534-18 

1 DIS 65-93534-10 

1 DIS 65-93534-14 

1 DIS 65-93534·16 

1 DIS 65-93534-15 

2 DIS 65·93534-7 

2 DIS 65-93534-8 

1 DIS 65-93534-14 

1 DIS 65-93534-22 

1 DIS 65-93534-20 

1 DIS 65-93534·17 

PNC 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

s 

RC 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

3477 

16 
BOEING SERVICE BULLETIN 3477 

DC Disposition Code 

DIS • Discard Part 

PNC Part Number Code 

S - New equivalent or replacement part number. 

RC Replacement Code 

A - Not interchangeable. Do not replace one part with the other. 

Jul26/90 

REV. 2: Apr 15/93 

3477 

17 
Jul26/90 

REV 2: Apr 15193 

BOEING SERVICE BULLETIN 3477 

BLANK PAGE 

3477 

18 
I 

BOEING SERVICE BULLETIN 3477 

Ill. ACCOMPLISHMENT INSTRUCTIONS 

NOTES: 

1. The paragraphs Identified with letters give the general work Instructions and the necessary 

tests. The Instructions Identified wilh numbers on the figures give the recommended sequence 

of operations. 

2. Unless specified differently, the dimensions and tolerances given below are used: 

- All linear dimensions are in inches 

- Tolerance on linear dimensions other than rivet and boil edge margin is plus or minus 

0.03 

- Tolerance on rivet and boll edge margin Is plus or minus 0.05 

- The hole dimensions for standard solid rivets are found In the 707 Structural Repair 

Manual, Chapter 51 

- The torque limits to tighten nuts and bolts are found In the 707 Structural Repair Manual, 

Chapter 51 

3. Refer to 707 Structural Repair Manual Chapter 51 for alternative fasteners. 

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

PART I · INSPECTION 

A. Do an inspection of the hinge fittings and the latch cams on the main cargo door as shown in Figure 1. 

B. If any of the four hinge fittings are worn beyond the limit given in Figure 1, Install new hinge fittings and 

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

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

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

PART II-REPLACEMENT 

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

B. Remove the Interior lining and the insulation from the lower area of the main cargo door (Reference - 707 

Maintenance Manual, Subjects 52-11-171 and 52-11-192). 

C. Place a work platform next to the airplane at the main cargo door. 

D. Partially open the main cargo door. Use wood blocks to support the door in the opened position as 

shown In the 707 Maintenance Manual, Subject52-11-0, Inspection/Check. Cycle the latch cams Into the 

locked position with the door In the open position as shown in the Maintenance Manual Subject 52·11·0. 

E. Remove pressure from the hydraulic system for the main cargo door (Reference • 707 Maintenance 

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

F. Remove the most forward and aft main cargo door latch actuators as shown in the 707 Maintenance 

Manual, Subject 52-11-11. 

Jul26/90 

REV. 2: Apr 15/93 

3477 

19 
BOEING SERVICE BULLETIN 3477 

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

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

pressure relief doors as shown In Flgure 5. circle notes 1 lhrough 9. 

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

bellcranks as shown In Figure 3. 

J Install the pressure relief door and locate the new hinge filtangs on the pressure relief doors as shown in 

Fagure 5, circle notes 10 through 26. 

K. Install the most forward and aft main cargo door latch actuators as shown tn the 707 Maintenance Manual 

Subject52-11-11 

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

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

main cargo door Into the completely closed position while this step Is done. 

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

operates correctly (Reference- 707 Maintenance Manual. Subject 52-34-0. Adjustment!Testl. 

NOTE· Inspect to make sure that the tab on the martong bracket is insened Into the Index hole in the 

cam. Also do a check to see Lf the martong bracket as visible through the viewpon in the cargo 

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

N. Do a test of the warning system lor the main cargo door to make sure that it operates correctly 

(Reference- 707 Maintenance Manual, Subject 52·70-00 or -01) 

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

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

0 Install the insulatJOn and the Interior Ianing on the tower area or the maan cargo door (Reference • 707 

Maintenance Manual, Subjects 52-11-171 and 52-11·192) 

R Restore airplane to servaceable condation. 

Jul26/90 

REV 2: Apr 15/93 

3477 

20 
BOEING SERVICE BULLETIN 3477 

Illustration Table of Contents 

Tille Page 

Figure 1. Inspection . . • • . • . . . . . . . . . . • . • . . . • • • . • . . • . • . . . • . • . • • . • . • . . . • . • • • • 22 

Figure 2. Alignment Tool Fabrication • • . . . • . . • • • • . • . • . . . . . . • • . . • . . . . • • • • • • • . • . 24 

Flgure 3. Latch Cam Replacement . . . . . • . . . . . . . . . • . . • • . . . . . . . . . . . . . . . . . . . . . . . 25 

Figure 4. Web Removal. . . . . . . . . . . . . . . . . • . . • . . • • . . • . . . . . . • . . • . . • . . • • . • • • • . . 31 

Figure 5. Hinge Fining Replacement . . . . . • • . . • . • . . • • . . • • . . • . . . . • • . . • • . . • . . . . . 32 

Figure 6. Web tnstallallon . . • . • . . . • . . . . • . . . . . • . • . . . . • . • . • . . . . . . . . • . . . . . . . • . . 36 

Jut26f90 3477 

REV. 2: Apr 15193 21 
ALMOST THE 

SAM E AS DETAIL I 

Jul26/90 

REV. 2: Apr 15193 

BOEING SERVICE BULLETIN 3477 

SEE DETAIL I 

INBD 

PRESSURE 

RELIEF 

DOOR 

PRESSURE 

RELIEF 

DOOR 

PRESSURE 

DOOR 

SEAL 

-

0. 1S INCH 

IIINIIIUM 

OVERLAP 

REQUIRED 

0.12 INCH 

MA X IliUM 

flAT ALLOWED 

FIGURE 1 INS PECTION 

3477 

22 
LATCH 

CAM 

BOEING SERVICE BULLETIN 3477 

FWD 

DETAIL I 

LATCH 

CAM 

The Instructions given below agree with the numbers shown inside the circle symbols in the figure: 

Do a visual inspection of the area on each latch cam that contacts a hinge fitting on a pressure rellef door 

(4 places). If the cam is notched as shown, or if the cam shows any damage beyond 0.05 inches deep 

from contact with the hinge fitting, replace the latch cams and the hinge fittings as shown In this service 

bulletin. 

2 Measure the tip or each hinge fitting as shown (4 places). If any or the hinge fillings are wom beyond the 

limit shown, replace the latch cams and the hinge fittings as shown In this service bulletin. Refer to the 707 

Maintenance Manual, Subject 52-11-0. 

NOTE Removal of the pressure relief door from the main cargo door can be necessary to do the 

Inspection given In Step 2, above. Instructions for removal of the pressure relief door are given In 

the 707 Maintenance Manual, Subject 52-11-43 

3. If either the cam or the hinge fitting is wom, measure the overlap as shown In view AA. Make sure that 

there Is minimum of 0.15 inch overlap. If there is less than a 0.15 Inch overlap. replace the cam and the 

hinge fittings as shown in this service bulletin 

Jul26/90 

REV. 2: Apr 15/93 

FIGURE 1. INSPECTION 

3477 

23 
'\ 

A 

BOEING SERVICE BULLETIN 3477 

9o• /-____ -_ ----- _ ......___' 

0. 54 R 

0.55 

0.84 R 

/ 0.86 

A 8 

l.OSOIA 1.10 • 

B 

L '<' j L j 

I - r 

0.50 0.50 

l____l ___ .J_J _l L___ _ _____J_l 

VIEW A-A VIE W B-B 

The instrucllons given below agree with the numbers shown inside the circle symbols in the figure: 

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

o 2024· T 42 aluminum rod. 1. 75 Inch outside diameter 

o 6061·T42 aluminum rod, 1.751nch outside diameter 

FIGURE 2. AUGNMENT TOOL FABRICATION 

Jul26/90 

REV. 2: Apr 15/93 

34n 

24 
Jul 26/90 

SEE 

DETAIL I 

DETAIL II 

REV. 2: Apr 15/93 

BOEING SERVICE BULLETIN 3477 

SEE 

DETAIL VI 

SEE 

DETAIL V 

e:> FWD 

~ INBD 

SEE 

DETAIL IV 

FIGURE 3. LATCH CAM REPLACEMENT 

MA IN 

CAR GO 

DOOR 

-.. see 

DETAIL I 

SEE DETAIL II 

DETA IL III 

3477 

25 
Jul26/90 

REV. 2: Apr 15/93 

BOEING SERVICE BULLETIN 3477 

e::> FWD 

DETAIL I 

AFT LATCH CAM AND BELLCRANK ASSEMBLY SHOWN, 

FOR WARD LATCH AND BELLCRANK ASSEMBLY OP POSI TE 

SHEAR WEB 

69-24209-() 

DETAIL II 

VIEW LOOKING FOR WARD 

FRA ME 

I 

Z .\1-1 LUG ASSEMBLY - ~ 9-66095-1 

Q INBD 

AFT LUG ASSEMBLY SHOWN, FO RWARD LUG ASSEMBLY OPPOSITE 

FIGURE 3. LATCH CAM REPLACEMENT 

3477 

26 
Jul 26190 

REV. 2: Apr 15193 

BOEING SERVICE BULLETIN 3477 

8EllCRANK 

II D 

DE TAIL IV 

FIGURE 3. LATCH CA M REPLACEMENT 

3477 

27 
Jul26/90 

LATCH 

AC TUATOR 

REV. 2: Apr 15/93 

BOEING SERVICE BULLETIN 3477 

DET AIL VI 

FIGURE3 ' LA TCHCA M REPLACEMENT 

3477 

28 
BOEING SERVICE BULLETIN 3477 

VIEWPORT-------_ \ 

DOOR 

SK IN 

@ 11ARKI NG 

--='*=~ / BR ACKET 

Q INBD 

VIEW A-A 

LATCH CAl! 

The Instructions given below apply to latch cams and bellcranks located at Body Stations 495, 530, 570, 

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

latch cam and beiiC<ank. See Details IV and V for complete figures that show replacement of the latch cam 

and bellcrank assembly located at Body Stations 530 and 570. The instructions given below agree with 

the numbers shown Inside the circle symbols in the figure: 

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

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

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

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

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

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

decorative enamel. On sleet shear web 69-24109-7 and ·8, finish trimmed areas with brush cadmium 

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

2 Remove the fasteners that attach the forward and aft Lug Assembly to the frame. 

3 Remove the fastener that attaches the latch actuator to the bellcrank. Keep the fastener for tater use. 

NOTE: If the fastener Is wom, corroded, or Is missing finish, use a new Bolt 66-17789-1. 

4 Remove and discard the fasteners that attach the bellcrank to the latch cams. 

5 Remove the bellcrank and the latch cams from the door, and discard the bellcrank and the latch cams. 

Jul26/90 

REV. 2: Apr 15/93 

FIGURE 3. LATCH CAM REPLACEMENT 

3477 

29 
BOEING SERVICE BULLETIN 3477 

6 Use a screw NAS602·7, two washers AN960P08L and a nut NAS679A08W to Install the marking 

bracket on the new latch cam. Make sure that the tab on the marl<ing bracket fits Into the index hole on 

the cam. Make sure that the cams are In the latched position, and verify that the marking bracket is 

visible through the viewport in the cargo door skin. 

CAUTION: Make sure that the correct marl<lng bracket is Installed on each cam as shown in Figure 3. 

There are lwo different part numbered marking brackets. If the wrong bracket Is Installed 

on the cam, It will not be visible through the viewport in the door skin when the door is in 

the latched position. 

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

and the new bellcrank. 

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

to dry before the next step Is done. 

9 Use the fasteners indicated to install the new latch cams and the new bellcrank in position on the cargo 

door. 

NOTE: Make sure that the forward an aft lug assembly are in place prior to the Installation of the most 

forward and aft latch cams and bellcrank. 

10 Attach the latch actuator to the new bellcrank. Use the fasteners that were kept when the instructions 

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

11 Install the Lug Assembly to the web. 

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

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

A Install a bolt NAS1104-20W with a washer BACW10P208S under the bolthead. Use a nut 

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

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

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

C Install a countersink boll BACB30EL5CN19 with a nul NAS679A5. Torque the nul with 60 to 65 

Inch-pounds. 

0 Install BACB30GY8A( )X lockbolt with a BACC30K8 Collar. 

FIGURE 3. LATCH CAM REPLACEMENT 

Jul26/90 

REV. 2: Apr 15/93 

3477 

30 
BOEING SERVICE BULLETIN 3477 

e:> FWD 

INBD 

The instrucUons given below agree with the numbers shown Inside the circle symbols In the figure: 

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

keep the access panel for later use. 

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

door. 

3 Remove and keep the web for later use. 

FIGURE 4. WEB REMOVAL 

Jul26/90 

REV. 2: Apr 15/93 

3477 

31 
SEE DETAIL I 

FOR DOOR 

EXTERNAL 

BOEING SERVICE BULLETIN 3477 

VIEW~ 

~ar;;.--

STA 

480 

I 

I 

e:> FIID 

~ INBD 

SEE DETAIL II 

STA 

600D 

<1Yi9 ,~ n u n n L ; / 

Jul26/90 

REV. 2: Apr 15193 

' 

DETAIL I 

DOOR EXTERNAL VIEII 

FIGURE 5. HINGE FITTING REPLACEMENT 

3477 

32 
SPACER 

7\13118123 - -- """"f 

rl 

~ 

I 

NUT 

7113 N 

- - 18123 

BOEING SERVICE BULLETIN 3477 

_, 

5 !24 

8 110111 •19(23 PRESSURE RELIEF DOOR 

1 

-- ---

HINGE FITTING 

~FWD 

DETAI L II 

f 9I_J3> HINGE FITTING 

£: ~ 

I 

/ 

... 7 113 18123 

HINGE BOLT 

NUT 

~-4 J 25 '--

BELLCRANK 

r 11 

' H 4 25 ... --- \ BOLT 

• 

I 4 125 SPACER 

SECTION A-A 

20122 

I 3 26 

.... 

/ - 16 21 

~ I ,. 

SECTION B-B PRESSURE "' \ 1 <" 

RELIEF_ 1 "" ..... J_21 !_9 

(2 PLACES) 

Jut26/90 

REV. 2: Apr 15/93 

DOOR 1

17 \_. _ f . ~. 

\ ~ 

15 

/ ., 

,...y 

'--

VIEW C-C 

(2 PLACES) 

FIGURE 5 HINGE FITIING REPLACEMENT 

I 

ALIGNMENT 

TOOLS 

3477 

33 
BOEING SERVICE BULLETIN 3477 

The instructions given below agree with the numbers shown Inside the circle symbols in the figure: 

1 Make sure that the pressure relief door is cJosed and seated against its cutout in the main cargo door. 

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

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

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

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

lnslalied as described in Step 16. below. 

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

pressure relief door. Temporarily plug or cap the open hydraulic tubes to make sure that hydraulic fiuid 

does not spill all over In Jhe pressure relief door area In the cargo door. 

4 Remove the nut, the bolt, the washers and the spacers from the beilcrank on the torque tube that Is 

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

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

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

6 Rotate the bell crank on the torque tube so that it Is out of the way of the pressure relief door. 

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

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

8 Remove the pressure relief door from the cargo door. 

9 Carefully drfli out the rivets that attach the hinge fittings to the pressure relief door. Discard the old hinge 

fittings. 

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

marks on the cargo door skin. 

11 Wedge the pressure relief door so that ills firmly seated In Its cutout on the cargo door. 

NOTE: Make sure that the outside surface of the pressure door is fiush with the outside skin of the 

main cargo door. Refer to the 707 Maintenance Manual, Subject 52-11-43. 

12 Put the alignment tools thai were made in Flgure 2 In the cup of the cam as shown 

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

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

exactly like It was before it was removed. 

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

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

FIGURE 5. HINGE FITTING REPLACEMENT 

Jui26/90 

REV. 2: Apr 15/93 
BOEING SERVICE BULLETIN 3477 

15 Rotate the hinge fittings untillhe tip touches the alignment tool as shown. 

NOTE: Make sure that there Is no interference between the cam and the hinge fitting. If the hinge 

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

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

that the removal of material is done so to maintain the radius of the part. Maintain a 63 AA 

surface finish or better. 

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

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

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

relief door In position in the cargo door. 

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

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

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

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

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

pressure relief door is removed. 

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

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

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

holes to the final size. 

NOTE: As an option, the operator may use HI-Loks BACB30FP8A( ) and collars BACC30M8 In place 

of rivets to install the hinge fitting to the pressure door. To use HI-Loks Carefully drill matching 

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

holes exist in the pressure relief door. 

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

fittings. 

22 Use rivets MS204 7068-14 or optional fasteners coated with sealant (Reference - BMS 5-95. Class A) to 

install the new hinge fittings on the pressure relief door. 

23 Put the pressure relief door in position in the cargo door and attach the hinge fittings to the pivot pOints 

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

installed exactly like it was before It was removed. and make sure that the pressure relief door moves 

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

24 Rotate the bellcrank on the torque tube that is above the pressure relief door Into correct position on the 

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

above, was done. Torque the nut with 25 to 35 inch-pOunds. 

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

bracket on the pressure relief door. Torque the nut with 25 to 35 inch-pounds. 

26 Install the two hydraulic tubes that were removed when Step 3. above. was done. 

FIGURE 5. HINGE FITIING REPLACEMENT 

Jul26/90 

REV 2: Apr 15/93 

34n 

35 
3, 

::; 

N 

~ 

~ 

Jul26/90 

BOEING SERVICE BULLETIN 3477 

~ 

~~~~~---~~- lf~l 

SEE DETAIL I 

( ~ Cl 4 PLACES) 

SEE DETA IL II 

~ 

,A B B B B B 

4 

I 

r "d 

a r 

I 

Bt 

0 

0 0) 

0 

Bj "' 

f Bf 

0 

at B 

I / ' 

0 

0 7 

Bt 8 

t 

1 I 2 

DETAIL I 

8 

FIGURE 6. WEB INSTALLATION 

1 

REV. 2: Apr 15/93 

e> FWD 

~ INBD 

3 

B._ ~ A 

s " 

A 

1 

A 

1 

A 

J 

A 

J 

A 

8 J l 

3 C24 PLACES> 

3477 

36 
BOEING SERVICE BULLETIN 3477 

Jt- a_ 

/ 

jl (24 PLACES) 

DETAIL II 

The instructions given below agree with the numbers shown inside the clrcle symbols In the figure: 

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

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

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

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

when the Instructions in Figure 3 were done. 

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

The Instructions given below agree with the leHer shown In the upper-left corner of the fastener symbols in 

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

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

a HI-Lok BACB30FP6·( ) with a collar BACC30M6. 

B lnstaU a rivet MS20470D6-7 (24 Places). 

FIGURE 6. WEB INSTALLATION 

Jul26/90 

REV. 2: Apr 15/93 

3477 

37 

BDIIND 

Number: 

Date: 

Revision 2: 

ATASystem: 

Prepared By: 

3477 

July 26. 1990 

April 15. 1993 

5211 

Mark Miller 

Commercial 

Airplane 

Group 

707/720 

Service Bulletin 

Evaluation Form 

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

DOOR HINGE FITIING REPLACEMENT 

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

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

Items: 

• Did this service bulletin meet your estimate or quality? 

- How easy Is this service bulletin to understand? 

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

- Will you do this service bulletin fully? II not, please tell us why. 

- Is the Manpower estimate satisfactory? 

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

changes. please use a Publication Change Request (PCR) form. 

Please give us this data: 

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PREPAREDBY: ---------------------------

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form. 

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

directly to this address: 

R.G. Kelsey. Manager 

Service Bulletin Engineering 

Boeing Commercial Airplane Group 

P.O. Box 3707, Mall Stop 2L·02 

Sea!Ue, WA 98124·2207 

BOEING COMMERQAJ... AJRPLANE CROUP P.O SOX 3107 SEAm£. WASHINGTON 93124·22D7