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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1214 Original Issue: June 17, 1999 Revision 5: January 30, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 1999 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 1 of 77
7.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 2 of 77 BOEING SERVICE BULLETIN 737-53A1214
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 2 4 B. Concurrent Requirements ...................................... 2 4 C. Reason ................................................ 2 4 D. Description .............................................. 2 6 E. Compliance .............................................. 2 7 F. Approval ............................................... 3 8 G. Manpower .............................................. 3 9 H. Weight and Balance Changes .................................... 4 1 I. Electrical Load Data ......................................... 4 1 J. References .............................................. 4 1
1. Existing Data: ......................................... 4 1
2. Data Supplied with this Service Bulletin: ........................... 4 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 2 K. Publications Affected ........................................ 4 2 L. Interchangeability and Intermixability of Parts ........................... 4 2 M. Software Accomplishment Summary ................................ 4 2
2. MATERIAL INFORMATION ........................................ 4 3 A. Material - Price and Availability ................................... 4 3 B. Industry Support Information .................................... 4 3 C. Parts Necessary for Each Airplane ................................. 4 3
1. Kits/Parts: ........................................... 4 3
2. Parts and Materials Supplied by the Operator: ........................ 4 3
3. Parts Modified and Reidentified: ............................... 4 3
4. Parts Removed and Not Replaced: .............................. 4 3 D. Parts Necessary to Change Spares ................................. 4 3 E. Special Tooling - Price and Availability ............................... 4 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 5 A. GENERAL INFORMATION ..................................... 4 5 B. WORK INSTRUCTIONS ....................................... 4 6 FIGURE 1: LFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM STRINGER S-15L TO S-15R ................................. 5 2 FIGURE 2: HFEC INSPECTION OF THE WEB AT THE "Y" CHORD IN THE UPPER BULKHEAD FROM STRINGER S-15L TO S-15R ................................. 5 4 FIGURE 3: ONE-TIME NDT INSPECTION OF WEB AT THE OUTER CIRCUMFERENTIAL TEAR STRAP .................................................. 5 6 FIGURE 4: NDT INSPECTION OF WEB AT THE "Y" CHORD IN THE LOWER BULKHEAD FROM STRINGER S-15LTO S-15R .................................. 5 8 FIGURE 5: DETAILED INSPECTION FOR OIL-CAN DAMAGE IN THE BULKHEAD WEB ...... 6 0 FIGURE 6: NDT INSPECTION OF THE DOME CAP AT THE CENTER OF THE BULKHEAD ..... 6 2 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 3 of 77 BOEING SERVICE BULLETIN 737-53A1214
ALERTALERT
FIGURE 7: NDT INSPECTION OF THE FORWARD FLANGE OF THE "Z" STIFFENER AT THE DOME C A P............................................... 6 4 Appendix A: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 3 OR 737-300/400/500 53-80-08 REPAIR 1 - TYPICAL REPAIR FOR DAMAGE TO WEB AND STRAP .................. 6 7 Appendix B: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 3 OR 737-300/400/500 53-80-08 REPAIR 1 - TYPICAL REPAIR FOR DAMAGE TO WEB ......................... 6 9 Appendix C: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 5 OR 737-300/400/500 SRM 53-80-08 REPAIR 2 ................................................. 7 0 Appendix D: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 12 OR 737-300/400/500 SRM 53-80-08 REPAIR 4 ................................................. 7 2 Appendix E: OBSOLETE 737-100/200 SRM 53-10-4 FIGURE 13 OR 737-300/400/500 SRM 53-80-08 REPAIR 5 ................................................. 7 5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 4 of 77 BOEING SERVICE BULLETIN 737-53A1214
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1214Original Issue: June 17, 1999 Revision 5: January 30, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Group 1: No more work is necessary on the airplane(s) changed or inspected in accordance with Revision 4 of this service bulletin. These airplanes will reach their limit of validity prior to the compliance time for the inspections added by this service bulletin revision.
Group 2: More work is necessary on the airplane(s) changed or inspected in accordance with Revision 4 of this service bulletin. Beginning at 76,000 total flight cycles, the repeat inspection interval is reduced for Non-Destructive Testing (NDT) inspections of the web at the "Y" Chord.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-18-13 R1 is related to this service bulletin.
The effective date of AD 2012-18-13 R1 is June 13, 2013.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin.
The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
REASON FOR REVISION This revision is sent to incorporate a Widespread Fatigue Damage (WFD) analysis for Group 2 airplanes.
Beginning at 76,000 total flight cycles, the repeat inspection interval is decreased for Non-Destructive Testing (NDT) inspections of the web at the "Y" Chord.
The data given in Alternative Method of Compliance Notice (AMOC) SB 737-53A1214-AMOC-01 is included in this revision.
The data given in Alternative Method of Compliance Notice (AMOC) SB 737-53A1214-AMOC-02 is included in this revision.
The data given in Global Alternative Method of Compliance Notice (GAMOC) 120S-12-630 is included in this revision.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 5 of 77
These sections were changed:
1. In Summary, changed Background and Compliance.
2. In Paragraph 1.A., Effectivity, Airplane line numbers 2566 to 3132 are moved from Group 1 into new Group 2.
3. In Paragraph 1.C., Reason, added Service Related Problem (SRP) 737-SRP-53-0417.
4. In Paragraph 1.E., Compliance, added the following:
– Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-18-13 R1 – Statement that the FAA will possibly release an additional Airworthiness Directive (AD) – Statement to do required actions in accordance with Paragraph 3. Accomplishment Instructions – Note pertaining to Limit of Validity of Line Number 1-291 airplanes – Group 1 heading to Table 1 and Table 2 – Table 9 to Table 11 for Group 2 airplanes
5. In Paragraph 1.F., Approval, changed to add AD 2012-18-13 R1.
6. In Paragraph 1.J., References, added Service Related Problem (SRP) 737-SRP-53-0417 and AD 2012-18-13 R1.
7. Added Paragraph 1.M., Software Accomplishment Summary.
8. In Paragraph 3.B., Work Instructions, changed the following:
– In Parts II-V, clarified repeat inspections are applicable to unrepaired structure.
– In PART VI, changed Part VI and deleted Step 2.
9. In Figure 3, changed Step Table footnote (a).
10. In Appendix B, changed to remove inspection of repair plate.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY June 17, 1999Original Issue:
June 22, 2000Revision 1:
May 24, 2001Revision 2:
January 19, 2011Revision 3:
December 16, 2011Revision 4:
January 30, 2015Revision 5:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 6 of 77 BOEING SERVICE BULLETIN 737-53A1214
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1214Original Issue: June 17, 1999 Revision 5: January 30, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND Cracks have been reported in four general areas on the aft pressure bulkhead: cracks in the web at the web-to-"Y" chord interface; cracks in the web at the outer circumferential tear strap; cracks in the web near the dome cap;
and cracks in the "Z" stiffeners near the dome cap. Undetected cracking could result in loss of ability to maintain cabin pressure, rapid decompression of the airplane, and significant structural damage to the aft fuselage.
Cracks reported in the web at the web-to-"Y" chord interface occurred in the aft row of fasteners connecting the web to the "Y" chord. In all of the cases, the cracks ran in the circumferential direction. Most of the cracks have been at Stringer S-6L and S-6R, but there have been reports of cracks at other locations. The airplanes had accumulated between 22,966 and 68,000 flight cycles and between 45,500 and 61,000 flight hours.
There have been two reports of cracking in the bulkhead web at the outer circumferential tear strap. The airplanes had 21,246 and 26,162 flight cycles and 17,500 and 24,132 flight hours respectively.
Since revision 2 of this service bulletin, there have been reports of cracking in the center of the web near the dome cap. The cracks occurred at the center of the bulkhead at the end of the web gore sections. The airplanes had accumulated more than 30,000 flight cycles and 36,000 flight hours. There have also been two reports of cracks located on the "Z" stiffeners forward flange at the attach location to the dome cap pan. The cracks extended from the outboard fastener hole and ran circumferentially.
Boeing Structural Item Interim Advisory (SIIA) SIIA 737-52 and SIIA 737-269 are related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-53-0109, 737-SRP-53-0116, 737-SRP-53-0155, and 737-SRP-53-0417 are related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 7 of 77
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Get access to the forward or aft side of the aft pressure bulkhead and do a Non-Destructive Test (NDT) inspection for any cracking in the web at the "Y" chord. If damage is found from the aft side, get access to the forward side of the bulkhead and do a High Frequency Eddy Current (HFEC) inspection for any cracking in the web at the "Y" chord for the section of web where the damage was found. If any cracking is found, repair the crack(s) in accordance with the Structural Repair Manual (SRM) or contact Boeing for repair instructions and do the repair.
From either side of the bulkhead, do a NDT inspection for any cracking in the web at the outer circumferential tear strap for 360 degrees. Also, do an inspection for oil-canning in the web of the entire bulkhead and do repeat inspections at the times shown in the Compliance Section. If any cracking is found, repair the crack(s) in accordance with the Structural Repair Manual (SRM) or contact Boeing for repair instructions and do the repair.
From the aft side of the bulkhead, do a NDT inspection for any cracking in the bulkhead web at the lap joints.
Do the inspection from the edge of the gore section at the center of bulkhead to approximately ten inches outboard of the center. Do repeat inspections at the times shown in the Compliance Section. If any cracking is found, repair the crack(s) in accordance with the Structural Repair Manual (SRM) or contact Boeing for repair instructions and do the repair.
EFFECTIVITY All 737-100/-200/-200C/-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-18-13 R1 is related to this service bulletin.
The effective date of AD 2012-18-13 R1 is June 13, 2013.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 8 of 77 BOEING SERVICE BULLETIN 737-53A1214
ALERTALERT
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. This airworthiness directive would make certain compliance tasks and times given in Revision 5 of this service bulletin mandatory for Group 2 airplanes.
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.
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 9 of 77 BOEING SERVICE BULLETIN 737-53A1214
ALERTALERT
BOEING SERVICE BULLETIN 737-53A1214
ALERT ALERT
NDT INSPECT THE WEB FOR CRACKING AT
THE OUTER CIRCUMFERENTIAL TEAR STRAP
BL VISUALLY INSPECT THE
WEB FOR OIL-CANNING 5-71- -S-7R ACCESS DOOR "Y" CHORD FRAME CHORD S-15L ~S-15R FWD WEB
INSPECT THE WEB ALONG THE AFT ROW NDT INSPECT THE
OF FASTENERS USING EDDY CURRENT WEB FOR CRACKING
AND VISUAL INSPECTION A-A AT THE CENTER OF B—B VIEW LOOKING FORWARD THE BULKHEAD
DOME PAN "Z" STIFFENER (TYPICAL) WEB (TYPICAL) FWD NDT INSPECT THE "Z" STIFFENER FLANGE
WHERE IT ATTACHES TO THE DOME PAN (24 PLACES) C-C S62272 Original Issue: June 17, 1999 Revision 5: January 30, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1214 Work - See page 1 for details. 10 of 77
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1214 Original Issue: June 17, 1999 Revision 5: January 30, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web Cracks - Inspection and Repair
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. Refer to PRR 35005-229R for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 737-100/200/200C/300/400/500 Series Airplanes, Line Numbers 1 - 2565.
-1 737-100/200/200C/300/400/500 Series Airplanes, Line Numbers 2566-3132.
-2 Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 GroupVariable Number 1PA001 - PA022 1PA099 1PA231 - PA232 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 11 of 77
GroupVariable Number 1PC001 - PC005 1PG001 - PG075 1PG199 1PG201 - PG230 1PG251 - PG255 1PG271 - PG279 1PG301 - PG314 1PG331 - PG332 1PG351 - PG356 1PG375 1PG401 - PG403 1PG431 - PG442 1PG471 - PG475 1PG501 - PG505 1PG571 - PG586 1PG621 - PG630 1PG651 - PG652 1PG701 - PG705 1PH001 1PH011 - PH013 1PH021 - PH024 1PH701 - PH715 1PH731 - PH732 1PH741 - PH743 1PJ001 - PJ009 1PJ031 - PJ032 1PJ071 - PJ072 1PJ101 - PJ119 1PJ201 - PJ219 1PJ301 - PJ302 1PJ551 - PJ552 2PJ553 - PJ561 2PJ601 - PJ615 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 17, 1999 737-53A1214Revision 5: January 30, 2015 12 of 77 BOEING SERVICE BULLETIN 737-53A1214