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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-52A1100 Original Issue: August 25, 1988 Revision 5: February 14, 2011 ATA System: 5231 SUBJECT: DOORS - Forward Cargo - Lower Forward and Aft Corner Inspection, Modification and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 1989 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 1 of 178
5.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 2 of 178 BOEING SERVICE BULLETIN 737-52A1100
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Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 9 B. Concurrent Requirements ...................................... 2 9 C. Reason ................................................ 3 0 D. Description .............................................. 3 2 E. Compliance .............................................. 3 5 F. Approval ............................................... 4 2 G. Manpower .............................................. 4 3 H. Weight and Balance Changes .................................... 4 4 I. Electrical Load Data ......................................... 4 4 J. References .............................................. 4 5
1. Existing Data: ......................................... 4 5
2. Data supplied with this Service Bulletin: ........................... 4 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 5 K. Publications Affected ........................................ 4 5 L. Interchangeability and Intermixability of Parts ........................... 4 6
2. MATERIAL INFORMATION ........................................ 4 7 A. Material - Price and Availability ................................... 4 7 B. Industry Support Information .................................... 4 9 C. Parts Necessary For Each Airplane ................................. 4 9
1. Kits/Parts: ........................................... 4 9
2. Parts and Materials Supplied by the Operator: ........................ 5 8
3. Parts Modified and Reidentified: ............................... 5 9
4. Parts Removed and Not Replaced: .............................. 5 9 D. Parts Necessary to Change Spares ................................. 5 9 E. Special Tooling - Price and Availability ............................... 6 0 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 1 A. GENERAL INFORMATION ..................................... 6 1 B. WORK INSTRUCTIONS ....................................... 6 2 FIGURE 1: INSPECTION .......................................... 7 2 FIGURE 2: FRAME REPLACEMENT AND PREVENTIVE MODIFICATION - GROUP 1 THROUGH GROUP 5 AIRPLANES ......................................... 7 7 FIGURE 3: FRAME REPLACEMENT AND PREVENTIVE MODIFICATION - GROUP 6 AIRPLANES . 102 FIGURE 4: PREVENTIVE MODIFICATION - GROUP 1 THROUGH GROUP 5 AIRPLANES ..... 1 2 1 FIGURE 5: LEVELING COMPOUND INSTALLATION .......................... 1 4 0 FIGURE 6: OUTER "T" CHORD REPAIR ................................ 1 4 2 FIGURE 7: OPTIONAL ACCESS HOLE FOR FRAME REPLACEMENT - GROUP 1 THROUGH 5 AIRPLANES .......................................... 1 4 7 FIGURE 8: INSTALL OPTIONAL "C" CHANNEL ............................. 1 5 0 FIGURE 9: MAKE A LARGE ACCESS COVER ............................. 1 5 3
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 3 of 178 BOEING SERVICE BULLETIN 737-52A1100
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FIGURE 10: MAKE OPTIONAL "C" CHANNEL .............................. 1 5 4 FIGURE 11: FORWARD CARGO DOOR - LOWER CROSS BEAM - FORWARD END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM DOUBLER INSTALLED AND A REPAIRED "T"-CHORD (WITH A "T"-CHORD SPLICE) .............. 1 5 5 FIGURE 12: FORWARD CARGO DOOR - LOWER CROSS BEAM - AFT END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM DOUBLER INSTALLED AND A REPAIRED "T"-CHORD (WITH "T"-CHORD SPLICE) ............... 1 5 8 FIGURE 13: FORWARD CARGO DOOR - LOWER CROSS BEAM - FORWARD END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM DOUBLER AND A WHOLE "T"-CHORD INSTALLED (NO "T"-CHORD SPLICE) ............... 1 6 1 FIGURE 14: FORWARD CARGO DOOR - LOWER CROSS BEAM - AFT END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM DOUBLER AND A WHOLE "T"-CHORD INSTALLED (NO "T"-CHORD SPLICE) ............... 1 6 4 FIGURE 15: FORWARD CARGO DOOR - LOWER CROSS BEAM - FORWARD END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM C-CHANNEL INSTALLED AND A REPAIRED "T"-CHORD (WITH A "T"-CHORD SPLICE) ....... 1 6 7 FIGURE 16: FORWARD CARGO DOOR - LOWER CROSS BEAM - AFT END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM C-CHANNEL INSTALLED AND A REPAIRED "T"-CHORD (WITH "T"-CHORD SPLICE) ........ 1 7 0 FIGURE 17: FORWARD CARGO DOOR - LOWER CROSS BEAM - FORWARD END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM C-CHANNEL AND A WHOLE "T"-CHORD INSTALLED (NO "T"-CHORD SPLICE) ............... 1 7 3 FIGURE 18: FORWARD CARGO DOOR - LOWER CROSS BEAM - AFT END - SUPPLEMENTAL
STRUCTURAL INSPECTION FOR AIRPLANES WITH A CROSS BEAM C-CHANNEL AND A WHOLE "T"-CHORD INSTALLED (NO "T"-CHORD SPLICE) ............... 1 7 6
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 4 of 178 BOEING SERVICE BULLETIN 737-52A1100
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-52A1100Original Issue: August 25, 1988 Revision 5: February 14, 2011 ATA System: 5231 SUBJECT: DOORS - Forward Cargo - Lower Forward and Aft Corner Inspection, Modification and Replacement This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes that had the frame replaced as an alternative to the installation of the modification angle, in accordance with the initial release, revision 1, 2, 3 and 4 of this service bulletin. Do a High Frequency Eddy Current (HFEC) inspection of the lower frame and number 5 cross-beam in accordance with this service bulletin at the revised time specified in Paragraph 1.E., Compliance.
More work is necessary for airplanes that have a preventive modification or a lower beam outer "T" chord repair installed in accordance with this Service Bulletin. Do the supplemental structural inspections in accordance with Revision 5 of this Service Bulletin.
No airplanes were added or deleted from the service bulletin effectivity.
REASON FOR REVISION This revision is sent to remove the option for repeat inspections and replace the visual beam inspection with a HFEC inspection. This revision is also sent to install preventive angle 65C27804-4 if the frame has been previously replaced. Instructions to install the access cover are changed to use permanent fasteners.
These sections were changed:
1. Paragraph 1.F., Approval - More data is added and some data is changed.
2. Summary Compliance and Paragraph 1.J.1., Existing Data - Added and changed Airworthiness Directive and Supplemental Structural Inspection Document references.
3. Paragraph 1.E., Compliance - Adjusted the compliance times, removed the data for repeat inspections, added 2 more rows to table 3, added table 4 and also added an Airworthiness Directive reference.
4. Summary Action and Paragraph 1.D., Description - Removed all the repeat inspection instructions and change visual inspection to a High Frequency Eddy Current (HFEC) inspection of the web and the outer 'T' chord of the lower cross beam.
5. Paragraph 1.J.1., Existing Data - Added Non-Destructive Test (NDT) manual figure references.
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Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 5 of 178
6. Paragraph 1.K., Publications Affected - A Damage Tolerance Based Structural Inspections statement is added.
7. Paragraph 3.A., Accomplishment Instructions - A note to install shims in all gaps greater than 0.005 inches is added to the General Notes. Also, a note regarding the use of the terms "refer to" and "in accordance with" is added to the General Notes.
8. Paragraph 3.B., Work Instructions - Added revision 4 to Part I and removed all the repeat inspection instructions.
9. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Changed the part number of a blind bolt and adjust the quantities of some blind rivets.
10. Paragraph 2.D., Parts Necessary to Change Spares - Changed three part numbers.
11. FIGURE 1 - Added references for step 1, open forward cargo door.
12. Removed 'Detail III' and change 'Detail I', 'Detail II' and two cross section views on the illustrations of FIGURE 1 to relate to the changed Step table. The Steps are changed to replace detail visual inspections with HFEC inspections.
13. Changed the fasteners with code A in FIGURE 1 from temporary to permanent ones.
14. FIGURE 1, FIGURE 2, and FIGURE 4 - The term "in accordance with" is used where another service bulletin is referenced in the illustrations.
15. Added notes in FIGURE 2 and FIGURE 4 which are related to the changes in FIGURE 1.
16. Changed the hole diameter for the fastener with code V in FIGURE 2 and FIGURE 3 and added an alternative fastener for the same code.
17. Paragraph 1.G., Manpower - Adjusted six values in the table.
18. Paragraph 1.D., Description and Paragraph 1.J.1., Existing Data - Added reference to service bulletin 737-52-1149.
19. Summary Background and Paragraph 1.C., Reason - Added information to give details of the causes and consequences of the cracks in the door. Also, added reference to Service Bulletin 737-52-1149.
20. Paragraph 3.B., Work Instructions - Part V is added to provide instructions for doing Supplemental Structural Inspections. Also, added instructions to Part I and Part V to do inspections in accordance with Service Bulletin 737-52-1149, if cracks are found.
21. FIGURE 11 through FIGURE 18 are added to provide Supplemental Structural Inspections.
The data given in Information Notice 737-52A1100 IN 07, 08 and 09 are included in this revision. IN 07 was sent to change the part number of the blind rivets in Paragraph 2.C.2., Parts and Materials Supplied by the Operator.
IN08 was superseded by IN09. IN09 was sent to change rivet part numbers in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, FIGURE 2 and FIGURE 3. It was also sent to amend the drawing numbers in Paragraph 2.D., Parts Necessary to Change Spares.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 6 of 178 BOEING SERVICE BULLETIN 737-52A1100
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Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY August 25, 1988Original Issue:
July 20, 1989Revision 1:
March 31, 1994Revision 2:
July 20, 2000Revision 3:
March 08, 2001Revision 4:
February 14, 2011Revision 5:
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 7 of 178 BOEING SERVICE BULLETIN 737-52A1100
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 8 of 178 BOEING SERVICE BULLETIN 737-52A1100
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-52A1100Original Issue: August 25, 1988 Revision 5: February 14, 2011 ATA System: 5231 SUBJECT: DOORS - Forward Cargo - Lower Forward and Aft Corner Inspection, Modification and Replacement
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 None.
BACKGROUND The Structures Task Group (STG) has examined the structural changes in this service bulletin, and recommends that the changes be included on 737 airplanes.
As of 1994, several operators had reported cracks in the forward cargo door. The cracks were occurring in the radius of the lower frames and in the web of the lower cross-beam. The cracks are caused by fatigue as a result of cabin pressurization cycles. Cracks in the radius of the corner frames ranged from 3/8 of an inch to 17.5 inches. Cracks in the number 5 cross-beam web ranged from 3/8th of an inch to 3 inches. Airplanes had accumulated 13,500 to 53,100 flight hours and 15,700 to 49,800 flight cycles. Undetected cracks could cause problems with cabin pressure stability with the possibility of rapid decompression.
Since 1994, there have been three reports from three operators of cracking in the radius of the lower aft frame on three airplanes. The airplanes were beyond the effectivity of the bulletin. The airplanes had accumulated 29,618 to 34,895 flight hours and 22,105 to 30,232 flight cycles.
Since the release of revision 2 of this bulletin, one operator experienced a rapid loss of cabin pressure during descent as a result of a door crack. Also since the release of revision 2, a few operators have experienced improper nesting when installing aft reinforcing angle 65C27804-4.
Since Revision 3, inputs from operators and further review of the bulletin has lead to some changes. A complete list of the changes is given in Paragraph 1.C., Reason.
The inspection, repair and preventive modification of the number 4 cross beam on the forward cargo door is the subject of the original issue of Boeing service bulletin 737-52-1149 .
Boeing Structural Item Interim Advisory SIIA 737-152 R1 is related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 9 of 178
Boeing Service Related Problem (SRP) 737-SRP-52-0057, 737-SRP-52-0070 and 737-SRP-52-0077 are related to this service bulletin.
Boeing Fleet Team Digest 737 FTD 52-01001, 737 FTD 52-02001 and 737 FTD 52-04004 are related to this service bulletin.
The Federal Aviation Administration (FAA) has issued an Airworthiness Directive (AD) which requires incorporation of this service bulletin.
ACTION (PRR 35420-R) On the forward cargo door, do a High Frequency Eddy Current (HFEC) inspection for cracks in the forward and aft lower end frame. Also, do a HFEC inspection for cracks in the web and "T" chord (lower chord) of the lower cross-beam.
If no cracks are found, install the frame preventive modification and the number 5 cross-beam modification/repair.
If cracks are found in the frame, replace the frame and install the frame preventive modification and the number 5 cross-beam repair/modification. If cracks are found in the number 5 cross-beam web, install the cross-beam repair/modification and the frame preventive modification. Also, do the inspection of the number 4 cross beam in accordance with the original issue of Boeing service bulletin 737-52-1149 at the time specified in Paragraph
1.E., Compliance . In addition, if the number 5 cross-beam outer chord (lower chord) is cracked, install the splice repair in accordance with this bulletin.
If you replaced the lower forward or lower aft frame in accordance with the initial release, revision 1, or revision 2 of this service bulletin, do an HFEC inspection for cracks in the frame. If no cracks are found, install the frame preventive modification. If cracks are found in the frame, replace the frame and install the frame preventive modification. Also, do the inspection of the number 4 cross beam in accordance with the original issue of Boeing service bulletin 737-52-1149 at the time specified in Paragraph 1.E., Compliance . If you installed aft frame preventive modification angle 65C27804-4 in accordance with revision 2 or 3 of this bulletin, then you need to do an inspection for proper fit. If the angle does not fit properly, you must replace it with a new angle. If you installed a properly fitting frame angle and a number 5 cross-beam doubler on a corner of the cargo door in accordance with the initial release, revision 1, 2, or 3 of this bulletin, then no action is necessary for the modified corner.
It is recommended that Boeing service bulletin 737-52-1149 and this service bulletin be incorporated concurrently.
Since both service bulletins remove fasteners in the door frame and inner skin, concurrent incorporation will minimize rework to these parts.
EFFECTIVITY 737-100/200/200C/300/400/500 series airplanes. Refer to Paragraph 1.A.1, Airplanes, for the list of affected airplanes.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directive AD 90-06-02 , AD 2000-07-06 , AD 2008-08-23 , AD 2008-09-13 and AD 98-11-04 R1 are related to this service bulletin.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 10 of 178 BOEING SERVICE BULLETIN 737-52A1100
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BOEING SERVICE BULLETIN 737-52A1100
ALERT ALERT
INDUSTRY SUPPORT INFORMATION This Service Bulletin was first issued before October of 1994. Therefore, there is no warranty statement included in this revision.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
STA 540 STA 460 STA 360
CROSS BEAM
WEB CRACK NUMBER 4
CROSS-BEAM
FRAME CRACK
17.5 INCH CRACK OUTBOARD RADIUS
OUTBOARD OF SEAL FWD E NUMBER 5 (LOWER) CROSS-BEAM CROSS BEAM WEB CRACK C15038 Original Issue: August 25, 1988 Revision 5: February 14, 2011 737-52A1100
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 178
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 25, 1988 737-52A1100Revision 5: February 14, 2011 12 of 178 BOEING SERVICE BULLETIN 737-52A1100