# Boeing Alert Service Bulletin 737-53A1200: U.S. DOT/FAA - Service Bulletin

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- Document: [Boeing Alert Service Bulletin 737-53A1200](https://openairdocs.org/service-documents/boeing/737-53a1200.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin
- Pages: 498
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### Page 1

Commercial
Airplanes
737
Service Bulletin
Number: 737-53A1200
Original Issue: April 13, 2006
Revision 2: September 12, 2012
ATA System: 5313
SUBJECT: FUSELAGE - Structure Around Openings - Forward Entry and Forward Galley Service
Doorway Upper and Lower Hinge Cutout - Inspection
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 © 2006 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Unpublished Work.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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management
Company.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
1 of 498
4.0

### Page 2

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### Page 3

Table of Contents
Revision Transmittal Sheet ............................................ 7
S u m m a r y ...................................................... 9
1. PLANNING INFORMATION ........................................ 1 3
A . E f f e c t i v i t y  ............................................... 1 3
1. Airplanes ............................................ 1 3
2 . S p a r e s  A f f e c t e d  ........................................ 2 9
B. Concurrent Requirements ...................................... 2 9
C. Reason ................................................ 2 9
D. Description .............................................. 3 0
E. Compliance .............................................. 3 1
F . A p p r o v a l  ............................................... 1 4 9
G. Manpower .............................................. 1 5 0
H. Weight and Balance Changes ................................... 1 6 3
I. Electrical Load Data ........................................ 1 6 3
J . R e f e r e n c e s  ............................................. 1 6 3
1. Existing Data: ......................................... 1 6 3
2. Data Supplied with this Service Bulletin: .......................... 1 6 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: .......... 1 6 4
K. Publications Affected ........................................ 1 6 4
L. Interchangeability and Intermixability of Parts ........................... 1 6 5
M. Software Accomplishment Summary ............................... 1 6 5
2. MATERIAL INFORMATION ....................................... 1 6 7
A. Material - Price and Availability .................................. 1 6 7
B. Industry Support Information .................................... 1 6 7
C. Parts Necessary for Each Airplane ................................ 1 6 7
1 . K i t s / P a r t s :  ........................................... 1 6 7
2. Parts and Materials Supplied by the Operator: ....................... 1 6 7
3. Parts Modified and Reidentified: ............................... 1 8 0
4. Parts Removed and Not Replaced: ............................. 1 8 0
D. Parts Necessary to Change Spares ................................ 1 8 0
E. Special Tooling - Price and Availability .............................. 1 8 0
F. Special Tooling Necessary to do this Service Bulletin ...................... 1 8 0
3. ACCOMPLISHMENT INSTRUCTIONS ................................. 1 8 1
A. GENERAL INFORMATION .................................... 1 8 1
B. WORK INSTRUCTIONS ...................................... 1 8 2
F I G U R E  1 : F O R W A R D  E N T R Y  D O O R  -  R A I N  G U T T E R  -  R E M O V A L  [ G r o u p  1 - 4 ,  6 - 9 ]  ........ 2 1 8
FIGURE 2: FORWARD GALLEY SERVICE DOOR - RAIN GUTTER - REMOVAL [Group 1-4, 6-8] . 220
FIGURE 3: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 1, 6, 9, Configuration 1] ................................ 2 2 2
FIGURE 4: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 1, 6, 9, Configuration 2] ................................ 2 2 8
FIGURE 5: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 2, 7-8] ......................................... 2 3 4
FIGURE 6: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 4] ............................................ 2 4 0
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### Page 4

FIGURE 7: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 1, 6, 9, Configuration 1] ................................ 2 4 6
FIGURE 8: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 1, 6, 9, Configuration 2] ................................ 2 5 2
FIGURE 9: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 2, 7-8] ......................................... 2 5 8
FIGURE 10: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 3] ............................................ 2 6 4
FIGURE 11: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 4] ............................................ 2 7 0
FIGURE 12: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT
INSPECTION [Group 1, 6, Configuration 1] ......................... 2 7 6
FIGURE 13: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT
INSPECTION [Group 1, 6, Configuration 2] ......................... 2 8 0
FIGURE 14: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT
INSPECTION [Group 2, 7-8] ................................. 2 8 4
FIGURE 15: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT
INSPECTION [Group 3-4] .................................. 2 8 8
FIGURE 16: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT
INSPECTION [Group 1, 6, Configuration 1] ......................... 2 9 2
FIGURE 17: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT
INSPECTION [Group 1, Configuration 2; Group 2; Group 6, Configuration 2; Group 7-8] . 296
FIGURE 18: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT
INSPECTION [Group 3-4] .................................. 3 0 0
FIGURE 19: FORWARD ENTRY DOOR - RAIN GUTTER - INSTALLATION [Group 1-4, 6-9] ..... 3 0 4
FIGURE 20: FORWARD GALLEY SERVICE DOOR - RAIN GUTTER - INSTALLATION [Group 1-4, 6-8]
................................................. 3 0 6
FIGURE 21: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
[Group 3] ............................................ 3 0 8
FIGURE 22: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION [Group
1, 6, 9, Configuration 1] .................................... 3 1 4
FIGURE 23: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION [Group
1, 6, 9, Configuration 2] .................................... 3 1 8
FIGURE 24: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION [Group
2 ,  7 - 8 ]  ............................................. 3 2 2
FIGURE 25: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION [Group
4 ]  ................................................ 3 2 6
FIGURE 26: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION [Group
3 ]  ................................................ 3 3 0
FIGURE 27: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION [Group
1, 6, 9, Configuration 1] .................................... 3 3 4
FIGURE 28: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION [Group
1, 6, 9, Configuration 2] .................................... 3 3 8
FIGURE 29: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION [Group
2 ,  7 - 8 ]  ............................................. 3 4 2
FIGURE 30: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION [Group
3 ]  ................................................ 3 4 6
FIGURE 31: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION [Group
4 ]  ................................................ 3 5 0
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### Page 5

FIGURE 32: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - DETAILED
INSPECTION [Group 1, 6, Configuration 1] ......................... 3 5 4
FIGURE 33: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - DETAILED
INSPECTION [Group 1, 6, Configuration 2] ......................... 3 5 8
FIGURE 34: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - DETAILED
INSPECTION [Group 2, 7-8] ................................. 3 6 2
FIGURE 35: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - DETAILED
INSPECTION [Group 3-4] .................................. 3 6 6
FIGURE 36: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - DETAILED
INSPECTION [Group 1, 6, Configuration 1] ......................... 3 7 0
FIGURE 37: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - DETAILED
INSPECTION [Group 1, Configuration 2; Group 2; Group 6, Configuration 2; Group 7-8] . 374
FIGURE 38: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - DETAILED
INSPECTION [Group 3-4] .................................. 3 7 8
FIGURE 39: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 1, 9, Configuration 1] ............. 3 8 2
FIGURE 40: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 1, Configuration 2; Group 8; Group 9, Configuration
2 ]  ................................................ 3 8 6
FIGURE 41: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 2] ........................ 3 9 0
FIGURE 42: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 3] ........................ 3 9 4
FIGURE 43: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 4] ........................ 3 9 8
FIGURE 44: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 1, 9, Configuration 1] ............. 4 0 2
FIGURE 45: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 1, Configuration 2; Group 8; Group 9, Configuration
2 ]  ................................................ 4 0 6
FIGURE 46: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 2, 4] ...................... 4 1 0
FIGURE 47: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT INSPECTION
OF SRM REPAIRED STRUCTURE [Group 3] ........................ 4 1 4
FIGURE 48: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT
INSPECTION OF SRM REPAIRED STRUCTURE [Group 1, Configuration 1; Group 8] . 418
FIGURE 49: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - EDDY CURRENT
INSPECTION OF SRM REPAIRED STRUCTURE [Group 2] ................ 4 2 4
FIGURE 50: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT
INSPECTION OF SRM REPAIRED STRUCTURE [Group 1, Configuration 2; Group 8] . 430
FIGURE 51: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - EDDY CURRENT
INSPECTION OF SRM REPAIRED STRUCTURE [Group 2] ................ 4 3 5
FIGURE 52: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 1, 9, Configuration 1] ............... 4 4 0
FIGURE 53: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 1, Configuration 2; Group 8; Group 9, Configuration 2]
................................................. 4 4 4
FIGURE 54: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 2] .......................... 4 4 8
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### Page 6

FIGURE 55: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 3] .......................... 4 5 2
FIGURE 56: FORWARD ENTRY DOORWAY - UPPER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 4] .......................... 4 5 6
FIGURE 57: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 1, 9, Configuration 1] ............... 4 6 0
FIGURE 58: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 1, Configuration 2; Group 8; Group 9, Configuration 2]
................................................. 4 6 4
FIGURE 59: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 2, 4] ........................ 4 6 8
FIGURE 60: FORWARD ENTRY DOORWAY - LOWER HINGE CUTOUT - DETAILED INSPECTION OF
SRM REPAIRED STRUCTURE [Group 3] .......................... 4 7 2
FIGURE 61: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - DETAILED
INSPECTION OF SRM REPAIRED STRUCTURE [Group 1, Configuration 1; Group 8] . 476
FIGURE 62: FORWARD GALLEY SERVICE DOORWAY - UPPER HINGE CUTOUT - DETAILED
INSPECTION OF SRM REPAIRED STRUCTURE [Group 2] ................ 4 8 0
FIGURE 63: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - DETAILED
INSPECTION OF SRM REPAIRED STRUCTURE [Group 1, Configuration 2; Group 8] . 484
FIGURE 64: FORWARD GALLEY SERVICE DOORWAY - LOWER HINGE CUTOUT - DETAILED
INSPECTION OF SRM REPAIRED STRUCTURE [Group 2] ................ 4 8 8
FIGURE 65: FORWARD GALLEY SERVICE DOORWAY - TORQUE TUBE ACCESS PANEL REMOVAL
[Group 1-2, 8] ......................................... 4 9 2
FIGURE 66: FORWARD GALLEY SERVICE DOORWAY - TORQUE TUBE ACCESS PANEL INSTALLATION
[Group 1-2, 8] ......................................... 4 9 4
FIGURE 67: FORWARD ENTRY DOORWAY - MAKE FILLER [Group 1-4, 6-9] ............ 4 9 6
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### Page 7

Commercial
Airplanes
737
Service Bulletin
Revision Transmittal SheetNumber: 737-53A1200Original Issue: April 13, 2006
Revision 2: September 12, 2012
ATA System: 5313
SUBJECT: FUSELAGE - Structure Around Openings - Forward Entry and Forward Galley Service
Doorway Upper and Lower Hinge Cutout - Inspection
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 in accordance with Revision 1 of this service bulletin.
REASON FOR REVISION
This revision is sent to correct errors and to make a change to the Compliance Tables.
These sections were changed:
1. Summary Background - A Summary Evaluation Table is added.
2. Paragraph 1.A.1., Airplanes - Revised the description of Group 9, Configuration 2 airplanes.
3. Paragraph 1.E., Compliance - Changed Compliance Time in Table 23. Changed compliance time in
multiple locations to state that grace period is based on Federal Aviation Administration (FAA)
Airworthiness Directive AD 2008-11-04 and not the original issue date of this service bulletin.
4. Paragraph 1.F., Approval - Changed SB revision number in multiple locations.
5. Paragraph 1.J.1., Existing Data - Two 737-100/200 AMM references are updated. Two AD references
are removed.
6. Paragraph 1.M., Software Accomplishment Summary - Section is added.
7. Paragraph 2.C.2., Parts and Materials Supplied by the Operator - Revised footnote references and
quantities for some fasteners. Deleted the table for Group 6, Configuration 2 and now Group 1,
Configuration 2 and Group 6, Configuration 2 share a common table.
8. Paragraph 3.B.3., Work Instructions - Changed reference from forward entry doorway to forward galley
service doorway in Part 4 and Part 5.
9. Paragraph 3.A., General Information Note 1 regarding the sequencing of steps is deleted. One note is
added.
10. Paragraph 3.B., Work Instructions - Two 737-100/200 AMM references are updated.
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### Page 8

11. Figure 67 - Changed a dimension on sheets 1 and 2, to correct a typographical error.
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 13, 2006Original Issue:
July 07, 2011Revision 1:
September 12, 2012Revision 2:
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### Page 9

Commercial
Airplanes
737
Service Bulletin
SummaryNumber: 737-53A1200Original Issue: April 13, 2006
Revision 2: September 12, 2012
ATA System: 5313
SUBJECT: FUSELAGE - Structure Around Openings - Forward Entry and Forward Galley Service
Doorway Upper and Lower Hinge Cutout - Inspection
CONCURRENT REQUIREMENTS
None.
BACKGROUND
Accomplishment of the inspections in this service bulletin will detect cracks in the skin, bearstrap and frame
outer chords in the upper and lower hinge cutout areas of the forward entry and forward galley service doorways.
Cracks that originate in the bearstrap or frame outer chord may not be detected with current inspection programs.
If cracks in the skin, bearstrap and frame outer chord are not detected they could cause a rapid decompression
of the airplane.
There have been multiple reports of cracks in the skin, bearstrap, and/or frame outer chord in the hinge cutout
areas of the forward entry and forward galley service door cutouts. Forward entry doorway bearstrap cracks
have been reported on an airplane with as few as 24,538 flight cycles. Forward galley service doorway bearstrap
cracks have been reported on an airplane with as few as 24,423 flight cycles. One operator reported a severed
bearstrap, severed STA 291.5 frame, and 14.5 inch long crack in the skin at the forward galley service doorway
lower hinge cutout. The airplane had accumulated 61,297 flight cycles.
Since the release of the original issue of this service bulletin, there have been fifteen reports of cracks in the
skin and/or bear strap at the forward galley service doorway hinge cutouts when the airplane had less than
40,000 total flight cycles. The lowest reported flight cycles on an airplane with a crack was 24,423 total flight
cycles. This airplane had a 0.55 inch long crack in the skin. There were no cracks in the bear strap. There have
also been four reports of cracking under repairs installed at the hinge cutouts in accordance with the Structural
Repair Manual (SRM).
Service Related Problem (SRP) 737-SRP-53-0134 and 737-SRP-53-0315 are related to this problem.
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., ComplianceYesAD Related
Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
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### Page 10

ReferenceAffectedPlanning Data
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
YesOperator Supplied Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
Group 1-4, 6-8:
Do an external detailed inspection, internal detailed inspection, and eddy current inspections for cracks in and
around the forward entry doorway and galley service doorway upper and lower hinge cutouts in the skin and
bearstrap and in the frame outer chord. If any crack is found, contact Boeing for repair instructions. If no cracks
are found continue to do the repeat inspections at the intervals specified in Paragraph 1.E., Compliance.
Group 9:
Do an external detailed inspection, internal detailed inspection, and eddy current inspections for cracks in and
around the forward entry doorway upper and lower hinge cutouts in the skin and bearstrap and in the frame
outer chord. If any crack is found, contact Boeing for repair instructions. If no cracks are found continue to do
the repeat inspections at the intervals specified in Paragraph 1.E., Compliance.
Group 5:
Contact Boeing for inspection instructions and do the work instructed by Boeing.
EFFECTIVITY
737-100, -200, -200C, -300, -400 and -500 series airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of
affected airplanes.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-11-04, AD 98-11-04 R1, AD 2008-08-23
and AD 2008-09-13 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service
bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
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### Page 11 (OCR)

BOEING SERVICE BULLETIN 737-53A1200
MATERIAL INFORMATION
Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
SEE
TYPICAL
CRACKS
UPPER HINGE
CUTOUT
INSPECT FOR CRACKS IN THE
SKIN, BEARSTRAP AND FRAME
CHORD, AROUND THE FORWARD
GALLEY AND FORWARD ENTRY
DOORWAY UPPER AND LOWER HINGE
CUTOUTS
TYPICAL
CRACKS
LOWER HINGE
CUTOUT
FWD
A RIGHT SIDE SIMILAR  J61169
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### Page 12

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BLANK PAGE

### Page 13

Commercial
Airplanes
737
Service Bulletin
Number: 737-53A1200
Original Issue: April 13, 2006
Revision 2: September 12, 2012
ATA System: 5313
SUBJECT: FUSELAGE - Structure Around Openings - Forward Entry and Forward Galley Service
Doorway Upper and Lower Hinge Cutout - Inspection
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.
DESCRIPTIONCONFIGURATIONGROUP
737-200 airplanes, line numbers 292 through 997 excluding Group
9 airplanes and airplanes delivered with hinge cutout external doublers
installed, variables PK901 through PK932 and PK971 through PK974.
-1
Without Service Bulletin 737-53-1074 Revision 3 incorporated.1
With Service Bulletin 737-53-1074 Revision 3 preventive modification
incorporated at the fwd entry door (skin trimmed and gap cover
installed between the upper and lower hinges) and at the fwd galley
door (skin trimmed and gap cover installed above the upper hinge
and with upper skin trimmed at the S-14R lap joint below the lower
hinge).
2
737-300, -400, -500 airplanes, line numbers 1001 through 1922. Skin
configuration has separate upper and lower skins at upper and lower
hinge cutouts on both doorways.
-2
737-300, -400, -500 airplanes line numbers 2350 and 2438 through
3132. Skin configuration has one skin at upper hinge cutout on both
doorways and a different fastener pattern at the lower hinge cutout
on the forward entry doorway.
-3
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### Page 14

DESCRIPTIONCONFIGURATIONGROUP
737-300, -400, -500 airplanes line numbers 1923 through 2437
excluding line number 2350. Skin configuration has one skin at upper
hinge cutout on both doorways and a different fastener pattern at the
lower hinge cutout on the forward entry doorway.
-4
737-100, -200, -200C airplanes, line numbers 1 through 291 with
cold bonded lap joints.
-5
737-200C airplanes, line numbers 294 through 992.-6
Without Service Bulletin 737-53-1074 Revision 3 incorporated.1
With Service Bulletin 737-53-1074 Revision 3 preventive modification
incorporated at the fwd entry door (skin trimmed and gap cover
installed between the upper and lower hinges) and at the fwd galley
door (skin trimmed and gap cover installed above the upper hinge
and with upper skin trimmed at the S-14R lap joint below the lower
hinge).
2
737-200C airplanes, line numbers 1002 through 1113. Skin
configuration has separate upper and lower skins at upper and lower
hinge cutouts on both doorways.
-7
737-200 airplanes, line numbers 998 through 1585. Skin configuration
has separate upper and lower skins at upper and lower hinge cutouts
on both doorways.
-8
737-200 airplanes that do not have a galley service door.-9
Without Service Bulletin 737-53-1074 Revision 3 incorporated.1
With Service Bulletin 737-53-1074 Revision 3 preventive modification
incorporated at the fwd entry door (skin trimmed and gap cover
installed between the upper and lower hinges).
2
Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500
GroupVariable Number
5PA001 - PA022
5PA099
5PA231 - PA232
5PC001 - PC005
5PG001 - PG075
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GroupVariable Number
5PG199
5PG201 - PG230
5PG251 - PG255
5PG271 - PG279
5PG301 - PG314
5PG331 - PG332
5PG351 - PG356
5PG375
5PG401 - PG403
5PG431 - PG442
5PG471 - PG475
5PG501 - PG505
5PG571 - PG583
1PG584 - PG586
5PG621 - PG630
5PG651 - PG652
5PG701 - PG705
1PH001
1PH011 - PH013
1PH021 - PH024
5PH701 - PH715
5PH731 - PH732
5PH741 - PH742
1PH743
5PJ001 - PJ002
1PJ003 - PJ009
5PJ031 - PJ032
5PJ071 - PJ072
5PJ101 - PJ104
1PJ105 - PJ119
9PJ201 - PJ219
4PJ301 - PJ302
3PJ551 - PJ561
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GroupVariable Number
3PJ601 - PJ615
3PJ811
3PJ816 - PJ817
1PK026 - PK029
1PK041 - PK053
1PK061 - PK070
1PK081 - PK082
1PK091 - PK099
1PK101 - PK103
1PK111 - PK120
1PK141 - PK146
1PK201 - PK204
1PK211 - PK215
8PK216 - PK220
1PK221 - PK223
1PK231 - PK241
1PK251 - PK258
1PK271 - PK274
1PK281 - PK289
1PK291
1PK301 - PK318
1PK341
1PK351 - PK361
1PK391
1PK431 - PK433
1PK451 - PK452
1PK461 - PK469
1PK495
1PK501 - PK504
1PK511 - PK514
8PK515
1PK519
1PK521 - PK525
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GroupVariable Number
8PK526 - PK528
1PK541 - PK564
8PK565
1PK581
1PK591 - PK599
1PK601 - PK617
1PK621 - PK637
1PK641 - PK642
1PK661 - PK664
8PK665 - PK666
1PK671 - PK680
8PK681
1PK691 - PK697
1PK711 - PK716
1PK731 - PK749
8PK750 - PK765
1PK771 - PK779
1PK801 - PK804
1PK819 - PK827
1PK830
1PK861 - PK863
1PK871 - PK874
1PK881 - PK884
8PK933 - PK938
1PL001 - PL028
1PL061
1PL081
1PL101 - PL113
1PL151
1PL171 - PL172
1PL201 - PL203
1PL221
1PL401 - PL417
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GroupVariable Number
1PL421
1PL441
1PL451 - PL454
8PL455 - PL456
1PL471
1PL491
1PL501 - PL506
1PL551 - PL562
1PL581
1PL601 - PL603
1PL611
1PL621 - PL623
8PL624 - PL626
1PL631 - PL632
5PL711 - PL712
5PL716
1PL717 - PL745
8PL746 - PL747
1PL756
1PL758
1PL761 - PL770
1PL781 - PL788
1PL793
5PL801 - PL803
1PM001 - PM006
1PM016 - PM017
1PM021 - PM023
1PM051 - PM062
8PM063 - PM066
1PM101 - PM119
1PM141 - PM142
8PM171
8PM181
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GroupVariable Number
8PM251 - PM255
8PM281 - PM283
2PM381 - PM392
4PM393 - PM399
4PM401 - PM414
3PM415 - PM417
4PM541
3PM542 - PM550
4PM551 - PM560
3PM561 - PM564
1PN001 - PN002
1PN021 - PN036
8PN037 - PN043
1PN081 - PN086
1PN101 - PN112
8PN113 - PN117
1PN131 - PN135
8PN136 - PN163
8PN401 - PN420
8PN431 - PN433
8PN451 - PN456
8PN471 - PN474
8PN481
8PN491 - PN493
8PN501 - PN502
8PN511 - PN512
8PN521
2PP001 - PP054
2PP101 - PP148
4PP149 - PP160
2PP161 - PP169
2PP181 - PP199
2PP201 - PP205
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GroupVariable Number
2PP221
2PP231 - PP243
2PP281 - PP286
2PP301 - PP305
2PP351 - PP353
2PP376 - PP384
2PP391 - PP393
2PP401 - PP440
2PP471 - PP475
2PP501 - PP510
4PP511 - PP517
3PP518 - PP520
2PP521 - PP522
2PP631 - PP634
2PP651 - PP652
2PP671 - PP699
2PP701 - PP733
2PP771 - PP779
2PP801 - PP808
2PP821 - PP827
2PP831 - PP848
2PP851 - PP852
2PP861 - PP873
4PP874
3PP875 - PP877
2PP891 - PP899
2PP901 - PP924
4PP925 - PP930
2PP931 - PP936
2PP946 - PP948
2PP951 - PP952
2PP961 - PP967
2PP981 - PP987
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GroupVariable Number
4PP988 - PP990
2PP991
2PP993
2PQ001 - PQ016
2PQ026 - PQ041
2PQ051 - PQ073
4PQ074 - PQ085
2PQ086 - PQ092
2PQ101 - PQ198
4PQ199
4PQ201 - PQ202
2PQ221 - PQ229
4PQ230
2PQ231 - PQ236
4PQ237
2PQ241 - PQ243
2PQ251 - PQ255
4PQ256 - PQ267
2PQ281 - PQ286
4PQ287 - PQ295
3PQ296 - PQ299
2PQ301 - PQ305
4PQ306 - PQ307
2PQ331 - PQ332
4PQ341 - PQ344
3PQ345 - PQ348
4PQ361 - PQ367
3PQ368 - PQ373
3PQ391 - PQ395
4PQ401 - PQ405
3PQ406 - PQ410
4PQ411 - PQ413
3PQ414 - PQ418
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GroupVariable Number
4PQ421
3PQ431 - PQ438
3PQ447 - PQ448
3PQ451
3PQ454
3PQ471 - PQ475
3PQ479 - PQ480
4PQ481
4PQ486
3PQ487
4PQ491 - PQ492
3PQ493
4PQ771
3PQ772
3PQ791 - PQ793
3PQ801 - PQ805
3PQ931 - PQ935
3PQ951
3PQ971 - PQ997
3PR001 - PR017
3PR021 - PR034
3PR041 - PR045
3PR061 - PR072
3PR077 - PR082
3PR091 - PR092
3PR096
3PR101
3PR121 - PR122
3PR131 - PR132
3PR141 - PR143
3PR161 - PR172
3PR181
4PS601 - PS616
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GroupVariable Number
3PS617 - PS630
4PS631
4PS636 - PS638
2PS641 - PS642
4PS643 - PS644
4PS651 - PS657
2PS666 - PS668
4PS669
4PS691 - PS692
4PS701 - PS703
3PS704 - PS706
4PS751 - PS752
3PS753 - PS799
3PS811
3PS836 - PS837
3PS841 - PS846
3PS851 - PS852
3PS856
3PS861 - PS863
3PS866 - PS868
3PS871 - PS874
3PS896 - PS897
3PS901 - PS941
3PS956 - PS957
3PS961 - PS963
3PS971 - PS978
4PT001 - PT011
3PT012 - PT015
2PT021 - PT023
4PT024 - PT026
3PT027 - PT031
4PT041 - PT059
3PT060 - PT064
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GroupVariable Number
2PT101
4PT102 - PT105
2PT121 - PT123
4PT124 - PT125
3PT126 - PT138
2PT146
4PT147 - PT148
4PT161 - PT169
3PT170
2PT181 - PT182
4PT183 - PT187
3PT188
2PT211 - PT214
4PT215 - PT220
2PT295
4PT301 - PT302
3PT303 - PT309
4PT331 - PT360
4PT381 - PT399
4PT401 - PT431
3PT432 - PT438
4PT501 - PT510
3PT511 - PT517
4PT561 - PT565
4PT581 - PT583
3PT584 - PT586
4PT611 - PT621
4PT641
3PT642 - PT644
4PT651 - PT654
3PT655 - PT656
4PT671
3PT672
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GroupVariable Number
3PT681 - PT685
4PT701 - PT703
3PT716 - PT717
3PT721 - PT725
3PT801 - PT834
3PT851 - PT854
3PT871 - PT886
3PT901 - PT930
3PT971 - PT973
3PT981 - PT985
3PT996
2PU001 - PU007
4PU008 - PU025
3PU301
3PU311 - PU313
2PV001 - PV040
4PV041 - PV055
4PV201 - PV202
3PV203 - PV209
3PV226 - PV229
4PV231 - PV237
4PV271 - PV272
3PV281 - PV287
3PV296
3PV301 - PV302
3PV351
3PV356 - PV357
2PW001 - PW036
4PW037 - PW050
2PW051
4PW052 - PW054
2PW061 - PW063
4PW064 - PW068
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GroupVariable Number
4PW072
3PW086 - PW088
2PW091 - PW093
4PW094
4PW101
3PW102
3PW106
2PW111 - PW117
4PW118 - PW120
4PW156 - PW157
2PW161 - PW162
4PW163 - PW166
3PW167 - PW171
4PW201 - PW216
3PW217 - PW230
4PW231 - PW237
3PW238 - PW252
4PW261
3PW262 - PW264
4PW265 - PW266
3PW267 - PW268
3PW271 - PW276
3PW278
4PW281
3PW282 - PW292
4PW293
4PW296
4PW301 - PW322
3PW323 - PW327
3PW401 - PW408
3PW411 - PW418
3PW421 - PW424
3PW431 - PW435
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GroupVariable Number
3PW441 - PW450
3PW461 - PW467
2PW501 - PW503
4PW504
2PW511 - PW518
4PW519 - PW520
3PW521 - PW522
3PW524 - PW530
2PW531 - PW535
4PW536 - PW544
3PW545 - PW550
3PW556 - PW557
2PW561 - PW563
4PW564
2PW571 - PW573
4PW574 - PW576
2PW591 - PW594
4PW595 - PW596
2PW611 - PW615
4PW616 - PW620
3PW621 - PW622
2PW631 - PW632
4PW633
3PW634 - PW637
2PW661
4PW662
4PW681 - PW683
4PW701 - PW702
4PW711 - PW716
3PW717
4PW741 - PW742
4PW761
3PW771
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GroupVariable Number
3PW831
3PW851 - PW856
5PX071
5PX701
5PY001 - PY008
5PY021
6PY022
5PY031
6PY036 - PY037
6PY046 - PY048
6PY051 - PY053
6PY056 - PY057
6PY101 - PY103
6PY111 - PY113
6PY131 - PY135
6PY141 - PY143
6PY151 - PY154
6PY156 - PY157
6PY161 - PY162
6PY166
6PY191
6PY201
6PY221 - PY222
6PY231
6PY241 - PY244
6PY270 - PY275
6PY281
6PY286
5PY301 - PY304
5PY321 - PY323
5PY341 - PY346
5PY361 - PY362
5PY381
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GroupVariable Number
6PY401
7PY409 - PY410
6PY411
6PY421 - PY422
6PY441
6PY451
6PY461 - PY462
7PY463
7PY591 - PY595
6PY611 - PY612
6PY621
6PY631
6PY651
6PY671 - PY672
7PY721
6PY741
2. Spares Affected
None.
B. Concurrent Requirements
None.
C. Reason
Accomplishment of the inspections in this service bulletin will detect cracks in the skin, bearstrap and
frame outer chords in the upper and lower hinge cutout areas of the forward entry and forward galley
service doorways. Cracks that originate in the bearstrap or frame outer chord may not be detected with
current inspection programs. If cracks in the skin, bearstrap and frame outer chord are not detected
they could cause a decompression of the airplane.
There have been multiple reports of cracks in the skin, bearstrap, and/or frame outer chord in the hinge
cutout areas of the forward entry and forward galley service door cutouts. Forward entry doorway
bearstrap cracks have been reported on an airplane with as few as 24,538 flight cycles. Forward galley
service doorway bearstrap cracks have been reported on an airplane with as few as 24,423 flight cycles.
One operator reported a severed bearstrap, severed STA 291.5 frame, and 14.5 inch long crack in the
skin at the forward galley service doorway lower hinge cutout. The airplane had accumulated 61,297
flight cycles.
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Since the release of the original issue of this service bulletin, there have been fifteen reports of cracks
in the skin and/or bear strap at the forward galley service doorway hinge cutouts when the airplane
had less than 40,000 total flight cycles. The lowest reported flight cycles on an airplane with a crack
was 24,423 total flight cycles. This airplane had a 0.55 inch long crack in the skin. There were no cracks
in the bear strap. There have also been four reports of cracking under repairs installed at the hinge
cutouts in accordance with the Structural Repair Manual (SRM).
Service Related Problem (SRP) 737-SRP-53-0134 and 737-SRP-53-0315 are related to this problem.
Revision 1 is sent to:
– Change the threshold for inspections at the galley service doorway upper and lower hinge cutouts.
– Add detailed and eddy current inspections of SRM repaired structure at the forward entry and
galley service doorway upper and lower hinge cutouts.
– Expand the detailed inspection area at the forward entry and galley service doorway upper and
lower hinge cutouts.
Revision 2 is sent to revise the description in the Group Configuration Table for group 9, change
Compliance Time in Table 23, revise footnote references and quantities for some fasteners in
Parts and Materials Supplied by the Operator tables, Change reference from forward entry doorway
to forward galley service doorway in Part 4 and Part 5 in the work instructions and to change
dimension in figure 67.
Revision 2 is sent to correct errors and to make a change to the Compliance Tables.
D. Description
Group 1-4, 6-8:
Do an external detailed inspection, internal detailed inspection, and eddy current inspections for cracks
in and around the forward entry doorway and galley service doorway upper and lower hinge cutouts
in the skin and bearstrap and in the frame outer chord. If any crack is found, contact Boeing for repair
instructions. If no cracks are found continue to do the repeat inspections at the intervals specified in
Paragraph 1.E., Compliance.
Group 9:
Do an external detailed inspection, internal detailed inspection, and eddy current inspections for cracks
in and around the forward entry doorway upper and lower hinge cutouts in the skin and bearstrap and
in the frame outer chord. If any crack is found, contact Boeing for repair instructions. If no cracks are
found continue to do the repeat inspections at the intervals specified in Paragraph 1.E., Compliance.
Group 5:
Contact Boeing for inspection instructions and do the work instructed by Boeing.
Revision 1:
– More work is necessary if the forward galley service doorway was not inspected and the airplane
has more than 20,000 total flight cycles. Initial Compliance thresholds are changed for inspections
at the forward galley service doorway. Refer to Paragraph 1.E., Compliance.
– More work is necessary if a repair has been installed in accordance with the Structural Repair
Manual (SRM) at the forward entry doorway or galley service doorway hinge cutouts. Do inspections
of the repaired area in accordance with Paragraph 1.E., Compliance.
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– No more work is necessary on airplanes inspected as given in the original issue of this service
bulletin if inspections were accomplished at both the forward entry doorway and the forward galley
service doorway and a SRM repair is not installed at the forward entry doorway or galley service
doorway hinge cutouts. Continue to do repeat inspections in accordance with Paragraph 1.E.,
Compliance.
– More work is necessary for Group 5 airplanes. Contact Boeing for inspection instructions and do
the work instructed by Boeing before further flight.
Revision 2 - No more work is necessary on the airplane(s) changed in accordance with Revision 1 of
this service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1, 8-9:
Affected Maintenance Zones
ZoneModel
1-5, 1-6737-200
Group 2-4:
Affected Maintenance Zones
ZoneModel
105, 106737-300, 737-400, 737-500
Group 5:
Affected Maintenance Zones
ZoneModel
1-5, 1-6737-100, 737-200, 737-200C
Group 6-7:
Affected Maintenance Zones
ZoneModel
1-5, 1-6737-200C
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-11-04, AD 98-11-04 R1, AD
2008-08-23 and AD 2008-09-13 are related to this service bulletin.
Group 5:
Contact Boeing for inspection instructions and do the work instructed by Boeing before further flight.
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### Page 32

Compliance Table Applicability
Forward Galley Service DoorwayForward Entry DoorwayGroup
Lower HingeUpper HingeLower HingeUpper Hinge
Compliance Table 26Compliance Table 19Compliance Table 10Compliance Table 11 Configuration 1
Compliance Table 27Compliance Table 21Compliance Table 11Compliance Table 21 Configuration 2
Compliance Table 29Compliance Table 24Compliance Table 13Compliance Table 42
Compliance Table 30Compliance Table 25Compliance Table 14Compliance Table 53
Compliance Table 30Compliance Table 25Compliance Table 15Compliance Table 64
N/A5
Compliance Table 26Compliance Table 20Compliance Table 16Compliance Table 76 Configuration 1
Compliance Table 28Compliance Table 21Compliance Table 17Compliance Table 86 Configuration 2
Compliance Table 28Compliance Table 22Compliance Table 12Compliance Table 37
Compliance Table 27Compliance Table 23Compliance Table 18Compliance Table 98
N/AN/ACompliance Table 10Compliance Table 19 Configuration 1
N/AN/ACompliance Table 11Compliance Table 29 Configuration 2
Group 1, 9, Configuration 1:
Table 1 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option A.
OR
3,000 flight
cycles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(1)(b). AND
Option B
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### Page 33

Group 1, 9, Configuration 1:
Table 1 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(1)(b).
18,000
flight cy-
cles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option B.
OR
3,000 flight
cycles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(1)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous HFEC
hole probe inspection (c)
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(1)(b).
or
within 3,000 flight cycles
from the initial LFEC inspec-
tion (d),
as applicable.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
33 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 34

Group 1, 9, Configuration 1:
Table 1 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
OR
3,000 flight
cycles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(1)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(1)(b).
12,000
flight cy-
cles.
Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Do an External and Internal Detailed In-
spection, High Frequency Eddy Current
(HFEC) Inspections and a Low Frequen-
cy Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.a.(4).
-Airplanes with
repair 737-
100/200 SRM
53-30-03, Fig-
ure 21 in-
stalled.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
34 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 35

Group 1, 9, Configuration 1:
Table 1 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (b)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found.
(a) It is acceptable to change inspection procedures from Option A to Option B or from Option B to Option A
if the operator does as follows: (1) If the inspection procedure has been changed from Option A to Option
B, then all inspections as given in Option B must be done within 18,000 flight cycles from the most recent
inspection given in Option A. (2) If the inspection procedure has been changed from Option B to Option
A, then all inspections as given in Option A must be done within 3,000 flight cycles from the most recent
LFEC inspection given in Option B.
(b) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
(c) For airplanes which have accomplished both the HFEC hole probe inspections and the external detailed,
HFEC, and LFEC inspections in accordance with the original issue of this service bulletin.
(d) For airplanes which have accomplished only the external detailed, HFEC and LFEC inspections, but not
the HFEC hole probe inspection, in accordance with the original issue of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
35 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 36

Group 1, 9, Configuration 2:
Table 2 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option A.
OR
3,000 flight
cycles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(2)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(2)(b).
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
36 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 37

Group 1, 9, Configuration 2:
Table 2 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option B.
OR
3,000 flight
cycles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(2)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous HFEC
hole probe inspection (c)
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(2)(b).
or
within 3,000 flight cycles
from the initial LFEC inspec-
tion (d),
as applicable.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
37 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 38

Group 1, 9, Configuration 2:
Table 2 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
OR
3,000 flight
cycles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(2)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(2)(b).
12,000
flight cy-
cles.
Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Do an External and Internal Detailed In-
spection, High Frequency Eddy Current
(HFEC) Inspections and a Low Frequen-
cy Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.a.(5).
-Airplanes with
repair 737-
100/200 SRM
53-30-03, Fig-
ure 21 in-
stalled.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
38 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 39

Group 1, 9, Configuration 2:
Table 2 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (b)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found
(a) It is acceptable to change inspection procedures from Option A to Option B or from Option B to Option A
if the operator does as follows: (1) If the inspection procedure has been changed from Option A to Option
B, then all inspections as given in Option B must be done within 18,000 flight cycles from the most recent
inspection given in Option A. (2) If the inspection procedure has been changed from Option B to Option
A, then all inspections as given in Option A must be done within 3,000 flight cycles from the most recent
LFEC inspection given in Option B.
(b) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
(c) For airplanes which have accomplished both the HFEC hole probe inspections and the external detailed,
HFEC, and LFEC inspections in accordance with the original issue of this service bulletin.
(d) For airplanes which have accomplished only the external detailed, HFEC and LFEC inspections, but not
the HFEC hole probe inspection, in accordance with the original issue of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
39 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 40

Group 7:
Table 3 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles.
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin.
18,000
flight cy-
cles.
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
-Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
repair 737-
100/200 SRM
53-30-03, Fig-
ure 21 in-
stalled.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
40 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 41

Group 7:
Table 3 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (a)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found
(a) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
41 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 42

Group 2:
Table 4 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.b.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option A.
OR
3,000 flight
cycles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(1)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(1)(b).
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
42 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 43

Group 2:
Table 4 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.b.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option B.
OR
3,000 flight
cycles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(1)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous HFEC
hole probe inspection (c)
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(1)(b).
or
within 3,000 flight cycles
from the initial LFEC inspec-
tion (d),
as applicable.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
43 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 44

Group 2:
Table 4 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.b.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
OR
3,000 flight
cycles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(1)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(1)(b).
12,000
flight cy-
cles.
Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Do an External and Internal Detailed In-
spection, High Frequency Eddy Current
(HFEC) Inspections and a Low Frequen-
cy Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(4).
-Airplanes with
737-300 SRM
53-10-01, Re-
pair 5 or 737-
400 SRM 53-
10-01, Repair
5 or 737-500
SRM 53-10-01,
Repair 5 in-
stalled at the
upper hinge
cutout.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
44 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 45

Group 2:
Table 4 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (b)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found
(a) It is acceptable to change inspection procedures from Option A to Option B or from Option B to Option A
if the operator does as follows: (1) If the inspection procedure has been changed from Option A to Option
B, then all inspections as given in Option B must be done within 18,000 flight cycles from the most recent
inspection given in Option A. (2) If the inspection procedure has been changed from Option B to Option
A, then all inspections as given in Option A must be done within 3,000 flight cycles from the most recent
LFEC inspection given in Option B.
(b) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
(c) For airplanes which have accomplished both the HFEC hole probe inspections and the external detailed,
HFEC, and LFEC inspections in accordance with the original issue of this service bulletin.
(d) For airplanes which have accomplished only the external detailed, HFEC and LFEC inspections, but not
the HFEC hole probe inspection, in accordance with the original issue of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
45 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 46

Group 3:
Table 5 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bearstrap and frame outer chord in
accordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option A.
OR
3,000 flight
cycles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(2)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(2)(b).
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
46 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 47

Group 3:
Table 5 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bearstrap and frame outer chord in
accordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option B.
OR
3,000 flight
cycles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(2)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous HFEC
hole probe inspection (c)
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(2)(b).
or
within 3,000 flight cycles
from the initial LFEC inspec-
tion (d),
as applicable.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
47 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 48

Group 3:
Table 5 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bearstrap and frame outer chord in
accordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
OR
3,000 flight
cycles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(2)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(2)(b).
12,000
flight cy-
cles.
Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Do an External and Internal Detailed In-
spection, High Frequency Eddy Current
(HFEC) Inspections and a Low Frequen-
cy Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(5).
-Airplanes with
737-300 SRM
53-10-01, Re-
pair 5 or 737-
400 SRM 53-
10-01, Repair
5 or 737-500
SRM 53-10-01,
Repair 5 in-
stalled at the
upper hinge
cutout.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
48 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 49

Group 3:
Table 5 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (b)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found
(a) It is acceptable to change inspection procedures from Option A to Option B or from Option B to Option A
if the operator does as follows: (1) If the inspection procedure has been changed from Option A to Option
B, then all inspections as given in Option B must be done within 18,000 flight cycles from the most recent
inspection given in Option A. (2) If the inspection procedure has been changed from Option B to Option
A, then all inspections as given in Option A must be done within 3,000 flight cycles from the most recent
LFEC inspection given in Option B.
(b) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
(c) For airplanes which have accomplished both the HFEC hole probe inspections and the external detailed,
HFEC, and LFEC inspections in accordance with the original issue of this service bulletin.
(d) For airplanes which have accomplished only the external detailed, HFEC and LFEC inspections, but not
the HFEC hole probe inspection, in accordance with the original issue of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
49 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 50

Group 4:
Table 6 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bearstrap and frame outer chord in
accordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option A.
OR
3,000 flight
cycles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(3)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(3)(b).
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
50 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 51

Group 4:
Table 6 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bearstrap and frame outer chord in
accordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option B.
OR
3,000 flight
cycles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(3)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous HFEC
hole probe inspection (c)
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(3)(b).
or
within 3,000 flight cycles
from the initial LFEC inspec-
tion (d),
as applicable.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
51 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 52

Group 4:
Table 6 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bearstrap and frame outer chord in
accordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.b.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
OR
3,000 flight
cycles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(3)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(3)(b).
12,000
flight cy-
cles.
Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Do an External and Internal Detailed In-
spection, High Frequency Eddy Current
(HFEC) Inspections and a Low Frequen-
cy Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.b.(6).
-Airplanes with
737-300 SRM
53-10-01, Re-
pair 5 or 737-
400 SRM 53-
10-01, Repair
5 or 737-500
SRM 53-10-01,
Repair 5 in-
stalled at the
upper hinge
cutout.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
52 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 53

Group 4:
Table 6 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (b)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found
(a) It is acceptable to change inspection procedures from Option A to Option B or from Option B to Option A
if the operator does as follows: (1) If the inspection procedure has been changed from Option A to Option
B, then all inspections as given in Option B must be done within 18,000 flight cycles from the most recent
inspection given in Option A. (2) If the inspection procedure has been changed from Option B to Option
A, then all inspections as given in Option A must be done within 3,000 flight cycles from the most recent
LFEC inspection given in Option B.
(b) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
(c) For airplanes which have accomplished both the HFEC hole probe inspections and the external detailed,
HFEC, and LFEC inspections in accordance with the original issue of this service bulletin.
(d) For airplanes which have accomplished only the external detailed, HFEC and LFEC inspections, but not
the HFEC hole probe inspection, in accordance with the original issue of this service bulletin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
53 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 54

Group 6, Configuration 1:
Table 7 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles.
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin.
18,000
flight cy-
cles.
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(1)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
-Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
repair 737-
100/200 SRM
53-30-03, Fig-
ure 21 in-
stalled.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
54 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 55

Group 6, Configuration 1:
Table 7 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (a)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found
(a) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
55 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 56

Group 6, Configuration 2:
Table 8 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles.
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin.
18,000
flight cy-
cles. (a)
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(2)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
-Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
repair 737-
100/200 SRM
53-30-03, Fig-
ure 21 in-
stalled.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
56 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 57

Group 6, Configuration 2:
Table 8 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
--No further action is required per this
service bulletin in the repaired area. (a)
-Airplanes with
a Boeing ap-
proved repair
installed at the
upper hinge
cutout which
meets the re-
quirements giv-
en in the Ac-
complishment
Instructions,
Paragraph
3.A.10. of this
service bul-
letin.
-Within 3,000 flight cycles
from the issue date of Revi-
sion 1 of this service bul-
letin.
Contact Boeing for further instructions
and do the work instructed by Boeing.
-Airplanes with
a repair in-
stalled at the
upper hinge
cutout that
does not meet
the above crite-
ria.
-Before further flightContact Boeing for repair instructions
and do the repair.
-If any crack is
found
(a) Supplemental inspections for the repaired area may still be required as given in the repair approval per
FAA Form 8100-9, or as specified in the Repair Assessment Guidelines documents.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
57 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 58

Group 8:
Table 9 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option A.
OR
3,000 flight
cycles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(3)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous inspec-
tion.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(3)(b).
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
58 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 59

Group 8:
Table 9 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have start-
ed inspections
in accordance
with the origi-
nal issue of
this service
bulletin and the
most recent in-
spection was
accomplished
using Inspec-
tion Option B.
OR
3,000 flight
cycles. (a)
Within 3,000 flight cycles
from the previous LFEC in-
spection.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(3)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 18,000 flight cycles
from the previous HFEC
hole probe inspection (c)
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(3)(b).
or
within 3,000 flight cycles
from the initial LFEC inspec-
tion (d),
as applicable.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
59 of 498
BOEING SERVICE BULLETIN 737-53A1200

### Page 60

Group 8:
Table 9 - Forward Entry Doorway - Upper Hinge Cutout - Inspections
Repeat In-
terval (Not
to Ex-
ceed)
Compliance Time
(Whichever Occurs Last)
ActionInspec-
tion Op-
tion
Condition
18,000
flight cy-
cles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External and Internal Detailed In-
spection, a High Frequency Eddy Cur-
rent (HFEC) Inspection and a HFEC
Hole Probe Inspection for cracking in the
skin, bonded doubler, bearstrap and
frame outer chord in accordance with
Accomplishment Instructions, Paragraph
3.B.2.a.(3)(a).
Option AAirplanes that
do not have an
external dou-
bler common
to the upper
hinge cutout
and have not
started inspec-
tions in accor-
dance with the
original issue
of this service
bulletin.
OR
3,000 flight
cycles. (a)
Within 3,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an External Detailed Inspection, a
HFEC Inspection and a Low Frequency
Eddy Current (LFEC) Inspection for
cracking in the skin, bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(3)(b). AND
Option B
18,000
flight cy-
cles. (a)
Within 6,000
flight cycles af-
ter June 25,
2008 (the effec-
tive date of AD
2008-11-04).
Before
20,000 to-
tal flight cy-
cles.
Do an Internal Detailed Inspection and
a HFEC Hole Probe Inspection for
cracking in the bonded doubler,
bearstrap and frame outer chord in ac-
cordance with Accomplishment Instruc-
tions, Paragraph 3.B.2.a.(3)(b).
12,000
flight cy-
cles.
Within 3,000
flight cycles af-
ter the issue
date of Revi-
sion 1 of this
service bul-
letin.
Within
12,000
flight cy-
cles after
the repair
was in-
stalled.
Do an External and Internal Detailed In-
spection, High Frequency Eddy Current
(HFEC) Inspections and a Low Frequen-
cy Eddy Current (LFEC) Inspection for
cracking in the skin, bearstrap and frame
outer chord in accordance with Accom-
plishment Instructions, Paragraph
3.B.2.a.(5).
-Airplanes with
repair 737-
100/200 SRM
53-30-03, Fig-
ure 21 in-
stalled.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: April 13, 2006
737-53A1200Revision 2: September 12, 2012
60 of 498
BOEING SERVICE BULLETIN 737-53A1200

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