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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1163 Original Issue: December 21, 1993 Revision 1: January 08, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Forward Entry Doorway Skin Cutout - Upper Forward and Upper Aft Corners - Inspection, Modification, 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 © 1993 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Unpublished Work.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 21, 1993 737-53A1163Revision 1: January 08, 2014 1 of 67
6.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 2 of 67 BOEING SERVICE BULLETIN 737-53A1163
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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 6 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 7 D. Description .............................................. 2 7 E. Compliance .............................................. 2 9 F. Approval ............................................... 3 1 G. Manpower .............................................. 3 2 H. Weight and Balance Changes .................................... 3 3 I. Electrical Load Data ......................................... 3 3 J. References .............................................. 3 3
1. Existing Data: ......................................... 3 3
2. Data Supplied with this Service Bulletin: ........................... 3 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 4 K. Publications Affected ........................................ 3 4 L. Interchangeability and Intermixability of Parts ........................... 3 5 M. Software Accomplishment Summary ................................ 3 5
2. MATERIAL INFORMATION ........................................ 3 7 A. Material - Price and Availability ................................... 3 7 B. Industry Support Information .................................... 3 7 C. Parts Necessary for Each Airplane ................................. 3 7
1. Kits/Parts ............................................ 3 7
2. Parts and Materials Supplied by the Operator ........................ 4 2
3. Parts Modified and Reidentified ................................ 4 3
4. Parts Removed and Not Replaced .............................. 4 3 D. Parts Necessary to Change Spares ................................. 4 3 E. Special Tooling - Price and Availability ............................... 4 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5 A. GENERAL INFORMATION ..................................... 4 5 B. WORK INSTRUCTIONS ....................................... 4 6 FIGURE 1: THIS FIGURE WAS DELETED AT REVISION 1 ....................... 5 1 FIGURE 2: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION [Group 1, Configuration 2; Group 3] .................................. 5 2 FIGURE 3: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - INSPECTION [Group 2, Configuration 2] ....................................... 5 6 FIGURE 4: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - CRACK REMOVAL [Group 1, Configuration 2] ................................... 6 0 FIGURE 5: FORWARD ENTRY DOORWAY - BEARSTRAP AND SKIN ASSEMBLY - CRACK REMOVAL [Group 2, Configuration 2] ................................... 6 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 3 of 67 BOEING SERVICE BULLETIN 737-53A1163
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 4 of 67 BOEING SERVICE BULLETIN 737-53A1163
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1163Original Issue: December 21, 1993 Revision 1: January 08, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Forward Entry Doorway Skin Cutout - Upper Forward and Upper Aft Corners - Inspection, Modification, and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes that have not installed the repair or preventive modification in accordance with the original issue of this service bulletin. Inspection areas are increased and inspections methods are changed.
No more work is necessary on the airplanes that have installed the repair or preventive modification in accordance with the original issue of this service bulletin.
737-300/-400/-500 airplanes line numbers 1923 to 3132 are added to new Group 3 of this service bulletin effectivity.
Federal Aviation Administration (FAA) Airworthiness Directives AD 98-11-04 R1, AD 2008-08-23 and AD 2008-09-13 are related to this service bulletin.
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.
REASON FOR REVISION This revision is sent to add new airplanes to the service bulletin effectivity. This revision is also sent to increase the inspection area, to remove internal inspection and to change external inspection methods for group 1 and 2 airplanes.
Airplane line numbers 1 through 291 are moved from Group 1 and 2 to new Group 4. 737-300/-400/-500 airplanes line numbers 1923 to 3132 are added to new Group 3 of this service bulletin effectivity.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. Title changed to add primary section affected by this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 5 of 67
2. Summary Section: Updated Background and added new service history, summary planning table, fleet team digest reference and service related problem reference.
3. Summary Section - Updated Action with increased inspection areas, changed inspection methods and instructions for new airplanes.
4. Summary Section - Updated Effectivity, Industry Support Information, Manpower and Material Information sections.
5. Summary Section - Compliance: Added related FAA Airworthiness Directives.
6. Paragraph 1.C., Reason - added new service history, fleet team digest reference, service related problem reference, reason for revision and Notice of Status Change 1 reference.
7. Paragraph 1.D., Description - Added increased inspection areas, changed inspection methods and instructions for new airplanes. Added maintenance zone tables.
8. Paragraph 1.E., Compliance - Added related FAA Airworthiness Directives. Added new compliance tables 1, 2 and 3.
9. Paragraph 1.F., Approval - Added new approval paragraph and alternative methods of compliance for related FAA Airworthiness Directives.
10. Paragraph 1.G., Manpower - Updated manpower tables for Group 1 and 2.
11. Paragraph 1.J., References - Existing Data list is updated and new drawing is added to Data Supplied with this Service Bulletin.
12. Paragraph 1.K.2., Damage Tolerance Based Structural Inspections - Added new section.
13. Paragraph 1.L., Interchangeability and Intermixability of Parts - Added new section.
14. Paragraph 1.M., Software Accomplishment Summary - Added new section.
15. Paragraph 2.A., Material - Price and Availability - Updated prices for all kits.
16. Paragraph 2.B., Industry Support Information - Updated warranty information.
17. Paragraph 2.C., Parts Necessary for Each Airplane - Added kit tables.
18. Paragraph 3.A., General Information - Added new notes.
19. Paragraph 3.B., Work Instructions - Updated instructions for Group 1 and 2. Added new instructions for Group 3.
20. Figure 1 has been deleted.
21. Figures 2 and 3 have been added to show increased inspection areas and changed inspection methods.
22. Figures 4 and 5 have been added to show crack removal.
The data given in Notice of Status Change 737-53-1163 NSC 1 related to inspections is not included in revision 1 of this service bulletin as the inspections have been replaced.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 6 of 67 BOEING SERVICE BULLETIN 737-53A1163
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The data given in Notice of Status Change 737-53-1163 NSC 1 related to kit prices is included in revision 1 of this service bulletin.
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 December 21, 1993Original Issue:
January 08, 2014Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 7 of 67 BOEING SERVICE BULLETIN 737-53A1163
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 8 of 67 BOEING SERVICE BULLETIN 737-53A1163
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1163Original Issue: December 21, 1993 Revision 1: January 08, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Forward Entry Doorway Skin Cutout - Upper Forward and Upper Aft Corners - Inspection, Modification, 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 Seventeen operators have found cracks in the upper corners of the forward entry door skin cutout. The airplanes had collected from 33,150 to 76,242 flight cycles. The cause of the cracks is fatigue from cabin pressure.
Continued operation with cracks in the doorway upper corners can result in cabin depressurization and unscheduled downtime for repairs.
Installation of doublers as given in this service bulletin can prevent cracks at the doorway upper corners.
Since the release of the original issue of this service bulletin there have been 3 reports of cracking at the forward entry doorway upper corners on airplanes that were outside the effectivity of the original issue of this service bulletin. The reports are listed below.
Service History ReportCycles/Hours 1 inch crack common to the bearstrap only found at the upper forward corner.59804 / 69512 Crack in the skin only at the upper aft corner.31238 / 37443 Crack in skin only at the upper forward corner.38126 / 46173 Boeing Fleet Team Digest (FTD) 737 FTD 53-11003 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-53-0381 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 9 of 67
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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Group 1-2, Configuration 1:
Airplanes with the repair/preventive modification installed in accordance with the original issue of this SB are not required to be inspected in accordance with the SB. Post repair/preventive modification inspections are provided in the D6-38669 Repair Assessment Guidelines document.
Group 1-2, Configuration 2; Group 3:
Get access to the upper corners of the forward entry doorway. Do an external detailed inspection and a Low Frequency Eddy Current (LFEC) inspection of the skin assembly and bearstrap for any crack at the upper corners of the forward entry doorway.
Group 1-2, Configuration 2:
If any crack is found in the skin assembly and/or bearstrap, install a repair in accordance with this service bulletin.
If no cracks are found, install the preventive modification or do repeat inspections at the times given in Paragraph
1.E., Compliance.
Group 3:
If any crack is found in the skin assembly and/or bearstrap, install a repair in accordance with this service bulletin and do repeat inspections of the area not covered by the repair at the times given in Paragraph 1.E., Compliance.
If no cracks are found, install the preventive modification or do repeat inspections of the entire inspection area at the times given in Paragraph 1.E., Compliance.
Group 4:
On Group 4 airplanes, contact Boeing to get instructions for the inspection and/or repair for this service bulletin, 737-53A1163 Revision 1, and do the work instructed by Boeing.
EFFECTIVITY All 737-100/-200/-200C/-300/-400/-500 Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 21, 1993 737-53A1163Revision 1: January 08, 2014 10 of 67 BOEING SERVICE BULLETIN 737-53A1163
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COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 98-11-04 R1, AD 2008-08-23 and AD 2008-09-13 are related to this service bulletin.
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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair/preventive modification procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Group 1-2, Configuration 1; Group 3-4:
None.
Group 1-2, Configuration 2:
Boeing Supplied Kits/Parts.
Group 1-2, Configuration 2:
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 21, 1993 737-53A1163Revision 1: January 08, 2014 11 of 67 BOEING SERVICE BULLETIN 737-53A1163
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BOEING SERVICE BULLETIN 737-53A1163
ALERT ALERT
TYPICAL UPPER
CORNER CRACKS
DO DETAILED AND
EDDY CURRENT
INSPECTIONS FOR
CRACKS IN THE SKIN
AND BEARSTRAP AT
THE UPPER PART OF
THE FORWARD ENTRY DOORWAY. IF ANY
CRACK IS FOUND
INSTALL A REPAIR
IF NO CRACKS ARE
FOUND, INSTALL THE
PREVENTIVE
MODIFICATION OR DO
REPEAT INSPECTIONS FORWARD ENTRY DOOR FWD 2191300 Original Issue: December 21, 1993 Revision 1: January 08, 2014 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1163 Work - See page 1 for details. 12 of 67