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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1188 Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change 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 © 1998 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Unpublished Work.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: April 09, 1998 737-53A1188Revision 3: September 06, 2013 1 of 99
5.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 2 of 99 BOEING SERVICE BULLETIN 737-53A1188
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 8 E. Compliance .............................................. 1 8 F. Approval ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 3 I. Electrical Load Data ......................................... 2 4 J. References .............................................. 2 4
1. Existing Data: ......................................... 2 4
2. Data Supplied with this Service Bulletin: ........................... 2 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 5 K. Publications Affected ........................................ 2 5 L. Interchangeability and Intermixability of Parts ........................... 2 5 M. Software Accomplishment Summary ................................ 2 5
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 8
1. Kits/Parts: ........................................... 2 8
2. Parts and Materials Supplied by the Operator: ........................ 3 1
3. Parts Modified and Reidentified: ............................... 3 2
4. Parts Removed and Not Replaced: .............................. 3 2 D. Parts Necessary to Change Spares ................................. 3 2 E. Special Tooling - Price and Availability ............................... 3 2 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 2
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 3 A. GENERAL INFORMATION ..................................... 3 3 B. WORK INSTRUCTIONS ....................................... 3 4 FIGURE 1: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 1] ..... 4 0 FIGURE 2: INSPECTION [Group 1] .................................... 4 4 FIGURE 3: REMOVAL OF STRUCTURE [Group 1] ............................ 4 8 FIGURE 4: THIS FIGURE HAS BEEN DELETED ............................. 5 3 FIGURE 5: THIS FIGURE HAS BEEN DELETED ............................. 5 4 FIGURE 6: THIS FIGURE HAS BEEN DELETED ............................. 5 5 FIGURE 7: CLOSE ACCESS - INSTALL SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 1] . 56 FIGURE 8: INSPECTION - DETAILED AND HIGH FREQUENCY EDDY CURRENT .......... 5 9 FIGURE 9: REMOVE REPAIR KIT 65C37762-2 AND -4 OR -6 ..................... 6 3 FIGURE 10: REMOVE PREVENTIVE MODIFICATION KIT 65C37762-1 AND -4 OR -5 ......... 6 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 3 of 99 BOEING SERVICE BULLETIN 737-53A1188
ALERTALERT
FIGURE 11: PREVENTIVE MODIFICATION OR REPAIR - NO KITS INSTALLED BY ORIGINAL ISSUE, REVISION 1 OR REVISION 2 [Group 1] ........................... 7 5 FIGURE 12: PREVENTIVE MODIFICATION OR REPAIR - REPLACES KITS INSTALLED BY ORIGINAL ISSUE OR REVISION 1 [Group 1] ............................... 8 2 FIGURE 13: ACCESS - REMOVE SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 2] .... 8 9 FIGURE 14: INSPECTION - DETAILED AND HIGH FREQUENCY EDDY CURRENT [Group 2] .... 9 3 FIGURE 15: CLOSE ACCESS - INSTALL SCUFF PLATE, REVEAL, AND LATCH FITTING [Group 2] . 95 FIGURE 16: POST Preventive Modification or Repair INSPECTION [Group 1] ............. 9 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 4 of 99 BOEING SERVICE BULLETIN 737-53A1188
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1188Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-17-03 is related to this service bulletin.
No more work is necessary on airplane(s) that have accomplished the repair or preventive modification in accordance with Revision 2 of this service bulletin.
Airplane line numbers 2766 thru 3132 were added as Group 2 of this service bulletin effectivity.
REASON FOR REVISION This revision is sent to add airplane line numbers 2766 thru 3132 to the effectivity of this service bulletin and to provide inspection and compliance information for these airplanes.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
The following sections are changed:
1. Summary, BACKGROUND, updated with additional information and added the Summary Evaluation Table.
2. Summary, ACTION, revised group 1 instructions, added group 2 instructions.
3. Summary, COMPLIANCE, added Airworthiness Directive (AD).
4. Summary, INDUSTRY SUPPORT INFORMATION, added applicability and group 2 standard statement.
5. Summary Illustration, updated with group 1 and group 2 applicability and added corresponding instructions.
6. Paragraph 1.A.1., Airplanes, updated effectivity and group configuration information.
7. Paragraph 1.C., Reason, updated with additional information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 5 of 99
8. Paragraph 1.D., Description, revised group 1 instructions, added group 2 instructions and updated maintenance zone data.
9. Paragraph 1.E., Compliance, added Airworthiness Directive (AD) reference, group 2 tables, and updated existing tables.
10. Paragraph 1.F., Approval, added an Alternative Method of Compliance (AMOC) statement.
11. Paragraph 1.G., Manpower, added table for Group 2 airplanes, and updated existing tables.
12. Paragraph 1.J.1., Existing Data, updated references.
13. Paragraph 1.K., Publications Affected, added new Damage Tolerance Inspection (DTI) statement.
14. Paragraph 2.A., Material - Price and Availability - The contact, price and ROLT information is updated.
15. Paragraph 2.B., Industry Support Information, added group 2 warranty standard statement.
16. Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added parts for Group 2 airplanes.
17. Paragraph 3.A., General Information - updated notes.
18. Paragraph 3.B., Work Instructions, added inspections instructions for group 2 airplanes, and updated group 1 instructions.
19. FIGURE 1, add applicability and updated a step.
20. FIGURE 2, FIGURE 3, and FIGURE 7 add applicability.
21. FIGURE 11 and FIGURE 12, add applicability, and updated the step table.
22. FIGURE 13, FIGURE 14, FIGURE 15 and FIGURE 16 are added for Group 2 airplanes.
The data given in Information Notice IN 02 is included in this revision. IN 02 was sent to advise operators of the correct NDT reference in Figure 11 and Figure 12 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 April 09, 1998Original Issue:
March 18, 1999Revision 1:
May 09, 2007Revision 2:
September 06, 2013Revision 3:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 6 of 99 BOEING SERVICE BULLETIN 737-53A1188
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1188Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change 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 This service bulletin gives instructions to inspect for cracking in the Body Station (STA) 303.9 web around the cut-outs for door stop straps at stringers 15 and 16, and to install a preventive modification or repair as necessary.
If the inspection or preventive modification or repair shown in this service bulletin is not completed, the web could crack at the strap cut-out inboard of stringer 16, and could crack at the strap cut-out inboard of stringer
15. This could result in not having support for the door stop assemblies at stringers 15 and 16 which could cause the forward entry door to not seal correctly and could cause in flight decompression.
Operators of 737 model airplanes line numbers 1 thru 2349 and 2351 thru 2437 have sent 7 reports on 7 airplanes of cracks at the cutout in the web of body station frame 303.9 inboard of stringer 16 left. The cracks were found between 37,562 and 64,000 flight cycles. This configuration has a 0.090 inch thick web with slot-shaped cut-outs, and a 0.071 inch thick doubler around the cut-out inboard of stringer 16. This configuration is the subject of service bulletin 737-53A1197.
737 model airplanes line numbers 2350 and 2438 thru 2765 have a 0.090 inch thick web with slot-shaped cut-outs for the straps for the door stop assemblies, without doublers around the web cut-outs. Fatigue analysis at Boeing shows that this configuration could crack after 10,000 flight cycles. The preventive modification or repair in this service bulletin applies to these airplanes. It changes the shape of the cutout in the web and installs a 0.090 thick doubler. A similar configuration exists on airplanes beyond line number 2765. These changes increase the fatigue life of the web.
737 model airplanes line number 2766 - 3132 also have 0.090 inch thick web but with elliptical-shaped cut-outs for the straps for the door stop assemblies and a 0.090 thick doubler around the S-16L web cut-out. The frame web cut-out for the strap at S-15 does not have a reinforcement doubler. The preventive modification or repair in this service bulletin does not apply to these airplanes. One crack was found in the frame web at a fastener hole adjacent to the S-15L web cutout. Similar cracks were also found on earlier line numbered airplanes. Cracks were found on airplanes with flight cycles from 28,843 to 46,458.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 7 of 99
Boeing Service Related Problem (SRP) 737-SRP-53-149 and 737-SRP-53-0381 are 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 AffectedYesPublications 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 (PRR 35328-R, PRR 35005-246RS) Group 1:
Do High Frequency Eddy Current (HFEC) and detailed inspections for cracking in the STA 303.9 web around the cut-outs for door stop straps at stringers 15L and 16L. If any crack is found in the web then do the preventive modification or repair. If no cracking is found then do repeat inspections at the interval specified in Paragraph
1.E., Compliance or do the preventive modification or repair.
Do post preventive modification or repair inspection.
Group 2:
Do HFEC and detailed inspections for cracking in the STA 303.9 web around the cut-out for the door stop strap at stringer 15L. If any crack is found in the web then contact Boeing for repair instructions and do the work instructed by Boeing. If no cracking is found then do repeat inspections at the interval specified in Paragraph
1.E., Compliance.
EFFECTIVITY 737-300, -400, -500 Airplanes. See Service Bulletin Paragraph 1.A.1 for effectivity.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-17-03 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 8 of 99 BOEING SERVICE BULLETIN 737-53A1188
ALERTALERT
The 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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Group 1:
Boeing warranty remedies are available for airplanes in warranty as of September 19, 1995. Refer to Paragraph
2.B., Industry Support Information.
Group 2:
Boeing warranty remedies are not available for the inspection(s), and/or repair(s) given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
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: April 09, 1998 737-53A1188Revision 3: September 06, 2013 9 of 99 BOEING SERVICE BULLETIN 737-53A1188
ALERTALERT
BOEING SERVICE BULLETIN 737-53A1188
ALERT ALERT STA
303.9 STA
303.9 GROUP 1:
-INSTALL NEW DOUBLER GROUP 1:
WL - -CHANGE THE SHAPE OF THE 208 WEB CUT-OUT TO AN
ELLIPTICAL SHAPE, IF NO
KITS WERE INSTALLED BY S-15 THE ORIGINAL ISSUE, REVISION 1 OR REVISION 2 GROUP 1: OF THIS SERVICE BULLETIN.
-INSTALL NEW SHORTER
STOP FITTING ASSEMBLY AT STRINGER 15. GROUPS 1 AND 2:
-DO A HFEC AND
DETAILED INSPECTION
FOR CRACKING AROUND THE WEB CUT-OUT.
GROUP 1:
-INSTALL NEW - 5-16 RADIUS FILLER.
GROUP 1:
GROUP 1: -DO A HFEC AND -INSTALL NEW SHORTER DETAILED INSPECTION
STOP FITTING ASSEMBLY FOR CRACKING AROUND AT STRINGER 16. WL THE WEB CUT-OUT.
208 GROUP 1:
-INSTALL NEW WEB →FWD SEGMENT.
• INBD GROUP 1 SHOWN, GROUP 2 SIMILAR FRAME AT STA 303.9 R98963 Original Issue: April 09, 1998 Revision 3: September 06, 2013 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1188 Work - See page 1 for detalls. 10 of 99
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1188 Original Issue: April 09, 1998 Revision 3: September 06, 2013 ATA System: 5313 SUBJECT: FUSELAGE - Body Station 303.9 Frame - Web Cracks at Holes for Door Stop Intercostal Strap at Stringers 15 and 16 Left - Preventive Change 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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-19567, Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. Refer to PRR 35005-246RS for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 737-300, -400, -500 airplanes, line numbers 2350, and 2438 thru 2765. These airplanes have slot-shaped cut-outs in the web for the straps for the door stop assemblies.
-1 737-300, -400, 500 airplanes, line numbers 2766 thru 3132. These airplanes have elliptical-shaped cut-outs in the web for the straps for the door stop assemblies and a doubler around the S-16L web cut-out.
-2 Airplane Models:
737-300, 737-400, 737-500 GroupVariable Number 1PJ551 - PJ559 2PJ560 - PJ561 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 11 of 99
GroupVariable Number 2PJ601 - PJ615 2PJ811 2PJ816 - PJ817 1PM415 - PM417 1PM542 - PM550 1PM561 - PM564 1PP518 - PP520 1PP875 2PP876 - PP877 1PQ296 - PQ299 1PQ345 - PQ346 2PQ347 - PQ348 1PQ368 - PQ372 2PQ373 2PQ391 - PQ395 1PQ406 - PQ410 1PQ414 2PQ415 - PQ418 1PQ431 - PQ438 2PQ447 - PQ448 2PQ451 2PQ454 1PQ471 - PQ474 2PQ475 1PQ479 - PQ480 1PQ487 1PQ493 1PQ772 1PQ791 - PQ793 1PQ801 - PQ805 1PQ931 - PQ935 2PQ951 2PQ971 - PQ997 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 09, 1998 737-53A1188Revision 3: September 06, 2013 12 of 99 BOEING SERVICE BULLETIN 737-53A1188