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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1108 Original Issue: December 15, 1986 Revision 7: July 07, 2014 ATA System: 5313 SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Galley Service Doorway, Aft Frame - Inspection and Repair 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.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 1989 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Unpublished Work.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: December 15, 1986 737-53A1108Revision 7: July 07, 2014 1 of 118
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 2 of 118 BOEING SERVICE BULLETIN 737-53A1108
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 7 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 7 D. Description .............................................. 2 9 E. Compliance .............................................. 3 1 F. Approval ............................................... 5 0 G. Manpower .............................................. 5 0 H. Weight and Balance Changes .................................... 5 3 I. Electrical Load Data ......................................... 5 4 J. References .............................................. 5 4
1. Existing Data: ......................................... 5 4
2. Data Supplied with this Service Bulletin: ........................... 5 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 5 5 K. Publications Affected ........................................ 5 5 L. Interchangeability and Intermixability of Parts ........................... 5 5 M. Software Accomplishment Summary ................................ 5 5
2. MATERIAL INFORMATION ........................................ 5 7 A. Material - Price and Availability ................................... 5 7 B. Industry Support Information .................................... 5 8 C. Parts Necessary for Each Airplane ................................. 5 8
1. Kits/Parts ............................................ 5 8
2. Parts and Materials Supplied by the Operator ........................ 6 1
3. Parts Modified and Reidentified ................................ 6 2
4. Parts Removed and Not Replaced .............................. 6 2 D. Parts Necessary to Change Spares ................................. 6 2 E. Special Tooling - Price and Availability ............................... 6 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 3 A. GENERAL INFORMATION ..................................... 6 3 B. WORK INSTRUCTIONS ....................................... 6 4 FIGURE 1: DOORWAY FRAME WEB AT STA 332.1 - INSPECTION [Group 1-4] ........... 8 0 FIGURE 2: DOORWAY BETWEEN STA 332.1 AND STA 344 - INTERCOSTAL AND STRINGER - INSPECTION [Group 1, 4, Configuration 2] .......................... 8 2 FIGURE 3: DOORWAY BETWEEN STA 322.1 AND STA 344 - INTERCOSTAL - REPAIR [Group 1] . 84 FIGURE 4: DOORWAY BETWEEN STA 322.1 AND STA 344 - INTERCOSTAL - PREVENTIVE MODIFICATION [Group 1, Configuration 2] .......................... 8 6 FIGURE 5: DOORWAY BETWEEN STA 322.1 AND STA 344 - INTERCOSTAL - PREVENTIVE MODIFICATION/REPAIR [Group 4, Configuration 2] ..................... 8 8 FIGURE 6: DOORWAY FRAME STA 332.1 - INTERCOSTAL T-BRACKET SURFACE AND RADIUS - INSPECTION [Group 1-4] ................................... 9 0 FIGURE 7: INTERCOSTAL AFT INBOARD WEB, FRAME STA 334 - INSPECTION [Group 1-2] . . . 98 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 3 of 118 BOEING SERVICE BULLETIN 737-53A1108
ALERTALERT
FIGURE 8: INTERCOSTAL T-CHORD - INSPECTION [Group 3] .................... 1 0 0 FIGURE 9: DOORWAY FRAME STA 334, SHEAR TIES AND STRINGER CLIPS - INSPECTION [Group 1-4] ............................................... 1 0 4 FIGURE 10: DOORWAY BETWEEN STA 332.1 AND STA 344 - INTERCOSTAL AND STRINGER - INSPECTION [Group 1-4] .................................. 1 0 9 FIGURE 11: DOORWAY BETWEEN STA 332.1 AND STA 344 - STRINGER - INSPECTION [Group 1-4] ................................................. 1 1 4 APPENDIX A: PARTS LIST FOR FORWARD SERVICE DOORWAY - AFT SURROUND STRUCTURE . 116 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 4 of 118 BOEING SERVICE BULLETIN 737-53A1108
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1108Original Issue: December 15, 1986 Revision 7: July 07, 2014 ATA System: 5313 SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Galley Service Doorway, Aft Frame - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed or inspected in accordance with Revision 6 of this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an additional 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) Airworthiness Directive AD 98-22-10 is related to this service bulletin.
FAA AD 98-22-10 supersedes AD 88-03-03.
REASON FOR REVISION This revision is sent to change Figure 8 step table and to correct typographical errors in Compliance Table 10 and Appendix A.
These sections were changed:
1. Paragraph 1.E., Compliance, Table 10, changed work instruction references.
2. Figure 8, Sheet 1, updated view callouts to match step table instructions.
3. Figure 8, Sheet 4, changed step table.
4. Appendix A, Sheet 3, changed Group applicability.
The data given in Information Notice 737-53A1108 R06 IN 01 is included 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 5 of 118
REVISION HISTORY December 15, 1986Original Issue:
March 26, 1987Revision 1:
August 13, 1987Revision 2:
March 03, 1988Revision 3:
November 17, 1988Revision 4:
October 26, 1989Revision 5:
January 09, 2014Revision 6:
July 07, 2014Revision 7:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 6 of 118 BOEING SERVICE BULLETIN 737-53A1108
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1108Original Issue: December 15, 1986 Revision 7: July 07, 2014 ATA System: 5313 SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Galley Service Doorway, Aft Frame - Inspection and Repair
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 As a result of the Federal Aviation Administration (FAA) sponsored Aging Fleet conference, a 737 Structures Working Group with Airline, Boeing members, and FAA observers was formed to review structural service bulletin modifications and recommend selected bulletins for incorporation on aging airplanes. This service bulletin modification has been recommended for incorporation on aging 737 airplanes.
Accomplishment of this service bulletin visual inspection of the forward service doorway aft frame around the six door stop fittings will identify structural cracking severe enough to weaken the door stop support structure.
A cracked doorway frame and supporting structure at two adjacent door stops can result in door deflection, loss of pressurization, and possible major structural damage to the doorway.
Four operators have reported eleven airplanes with cracks in the forward service doorway aft frame at door stop locations, supporting intercostals and stringers just aft of the frame, or in both the frame and the supporting structure. In four airplanes there was at least one intercostal completely severed.
The reported airplanes had accumulated from 16,100 to 45,400 flight hours, and from 19,200 to 51,300 total flight cycles.
Since the release of Revision 5 of this service bulletin Boeing has received multiple reports of crack damage in the forward galley service doorway surround structure, between Body Station (STA) 332.1and STA 344 that are outside the inspection area and effectivity of the service bulletin. The following list is a summary of safety related crack reports:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 7 of 118
– There have been four reports of cracking of the door stop 1 intercostal T-Bracket occurring at radius of the intercostal T-Bracket on airplanes that have accumulated between 27,938 and 78,547 total flight cycles.
There has been one report of a intercostal T-Bracket crack on an aircraft that had accomplished the preventive modification in accordance with Revision 5 of this service bulletin. Intercostal T-Bracket cracks have also been reported on aircraft outside the effectivity of Revision 5 of this service bulletin. Multiple operators have reported severed intercostal T-Bracket resulting in extensive cracking around the STA 332.1 door stop 1 fitting.
– There has been one report of a door stop 2 intercostal T-Bracket crack occurring at the frame attach flange on an aircraft that had accumulated 62,528 total flight cycles.
– There have been three reports of cracking of the door stop 1 intercostal T-Chord occurring at the forward trim radius of the T-Chord on airplanes that have accumulated between 37,684 and 63,305 total flight cycles.
Multiple operators have reported severed T-Chords resulting in extensive cracking at the intercostal web and around the STA 332.1 door stop 1 fitting.
– There have been two reports of STA 332.1 frame web cracking around the door stop 1 fitting without associated intercostal cracking on aircraft that had accumulated 62,272 and 62,528 total flight cycles.
– There have been three reports of cracking of the door stop 3 intercostal web occurring at the aft inboard trim radius on aircraft that have accumulated as low as 38,847 total flight cycles. All three aircraft had accomplished the preventive modification in accordance with Revision 5 of this service bulletin.
In addition Boeing has received reports of cracking that have been determined not to be a safety issue. These crack reports are summarized in the following list:
– There have been three reports of door stop 3 and 4 intercostal web cracks occurring at the aft outboard bend radius of the integral skin attachment flange on aircraft that had accumulated between 36,648 and 63,305 total flight cycles.
– There have been multiple reports of STA 344 stringer clip cracking occurring on aircraft that have accumulated as low as 22,147 total flight cycles.
– There have been two reports of STA 344 shear tie cracking occurring as early as 31,077 total flight cycles.
Boeing Service Related Problem (SRP) 737-SRP-53-0380 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 8 of 118 BOEING SERVICE BULLETIN 737-53A1108
ALERTALERT
ReferenceAffectedPlanning Data Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 34320R) Group 5:
Contact Boeing for inspection, modification and/or repair instructions and do the work instructed by Boeing.
Group 1, 4, Configuration 2:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill at stringer 17 for any crack. Do a detailed inspection, at all 6 door stop locations, of all the intercostal T-Brackets, do the applicable inspection of the intercostals and attaching stringers, and a High Frequency Eddy Current (HFEC) inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius for any crack.
Group 1, Configuration 1; Group 2; Group 4, Configuration 1:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill at stringer 17 for any crack. Do a detailed inspection, at all 6 door stop locations, of all the intercostal T-Brackets, and a HFEC inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius for any crack.
Group 3:
Do a detailed inspection of STA 332.1 frame web between the upper sill at stringer 7 and the lower sill at stringer 17 for any crack. Do a detailed inspection at all 6 door stop location of all the intercostal T-Brackets and T-Chords, and a HFEC inspection at door stops 1, 2, 5 and 6 intercostal T-Bracket radius and T-Chords for any crack.
Group 1-2; Group 4, Configuration 2:
Do a HFEC inspection at each door stop 3, 4 and 5 intercostal web that has not had a modification to remove and repair the original intercostal web.
Group 1-4:
If cracks are found in the Intercostal T-Brackets and/or T-Chords, remove and replace with identical part.
If no crack is found, do repeat inspection in accordance with Paragraph 1.E., Compliance.
OR Do the preventive modification at each inspected location in accordance with Paragraph 3.B., Work Instructions, PART 5, as follows:
Group 1-4:
Preventive Modification
1. Group 1, 4, Configuration 2:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets, and install the preventive modification and/or repair at each door stop 1 thru 6 intercostal location that has not already been modified.
2. Group 1, Configuration 1; Group 2; Group 4, Configuration 1:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 9 of 118 BOEING SERVICE BULLETIN 737-53A1108
ALERTALERT
3. Group 3:
Remove and replace door stops 1, 2, 5 and 6 intercostal T-Brackets and T-Chords.
NOTE: Post repair and post preventive modification inspections are provided in Paragraph 1.E., Compliance.
Revision 7 - No more work is necessary on the airplane(s) changed or inspected in accordance with Revision 6 of this service bulletin.
EFFECTIVITY 737-100/200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 98-22-10 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Group 1-4:
Refer to Paragraph 1.E., Compliance.
Group 5:
Contact Boeing to get instructions for the inspection, change or repair for this service bulletin, and do the work instructed by Boeing.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures 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: December 15, 1986 737-53A1108Revision 7: July 07, 2014 10 of 118 BOEING SERVICE BULLETIN 737-53A1108
ALERTALERT
BOEING SERVICE BULLETIN 737-53A1108
ALERT ALERT STA DO A DETAILED 332.1
INSPECTION FOR
CRACKS IN THE
INTERCOSTAL AT DOOR STOP 1 THRU 6
AND DO THE REPAIR
AS INSTRUCTED STA 344
UPPER SILL STOP 1 INSPECT FOR CRACKS 5S-7
IN DOORWAY FRAME DO A DETAILED WEB AT STA 332.1, IN INSPECTION OF
AREA SURROUNDING THE UPPER AND ALL 6 DOOR STOPS S-8A LOWER RADIUS OF WHERE NECESSARY. AND DO THE REPAIR STOP 2-10 T-BRACKET IN ALL SIX DOOR STOP LOCATIONS. IF ANY S-9 CRACK IS FOUND,
REPLACE THE T-BRACKET.
STOP 3 - Š-10A
DO A DETAILED
INSPECTION FOR
CRACKS IN DO HFEC INSPECTION OF EACH INTERCOSTAL STOP 4 S-11 AND ALL ATTACHED STRINGERS 9, AND 11,
FOR CRACKS IN THE AFT STRINGER CLIPS TRIM RADIUS.
STOP 5 S-12 DO A DETAILED S-13
INSPECTION FOR CRACKS IN THE STOP 6 SHEAR TIES. S-14 DO A DETAILED
INSPECTION FOR
CRACKS IN STRINGERS S-15 13, 14, AND 15 AND ALL
ATTACHED STRINGER CLIPS.
S-16
DO A DETAILED
INSPECTION FOR CRACKS
IN DOOR WAY FRAME WEB S-17 AT STA 344 BETWEEN UPPER SILL AT S-7 AND LOWER LOWER SILL S-17. 2182179 SILL Original Issue: December 15, 1986 Revision 7: July 07, 2014 Export Controlled ECCN: 9E991 - BOEING 737-53A1108 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 118
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 15, 1986 737-53A1108Revision 7: July 07, 2014 12 of 118 BOEING SERVICE BULLETIN 737-53A1108