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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1234 Original Issue: June 13, 2002 Revision 2: November 24, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Cracks at Chem-milled Steps - Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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 the Boeing livery 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 1 of 247
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 2 of 247 BOEING SERVICE BULLETIN 737-53A1234
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 6 E. Compliance .............................................. 1 8 F. Approval ............................................... 3 5 G. Manpower .............................................. 3 6 H. Weight and Balance Changes .................................... 4 0 I. Electrical Load Data ......................................... 4 1 J. References .............................................. 4 1
1. Existing Data: ......................................... 4 1
2. Data supplied with this Service Bulletin: ........................... 4 1
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
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 5
4. Parts Removed and Not Replaced: .............................. 4 5 D. Parts Necessary to Change Spares ................................. 4 5 E. Special Tooling - Price and Availability ............................... 4 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 7 A. GENERAL INFORMATION ..................................... 4 7 B. WORK INSTRUCTIONS ....................................... 4 8 FIGURE 1: LOGIC DIAGRAM - SKIN INSPECTIONS IN THE CROWN AREA ............. 5 8 FIGURE 2: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 1] .......... 5 9 FIGURE 3: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 3] .......... 6 2 FIGURE 4: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 4] .......... 6 5 FIGURE 5: FUSELAGE - STRINGER 4 PERMANENT SKIN REPAIR .................. 6 8 FIGURE 6: FUSELAGE - STRINGER 4 - 3.0-3.54 INCH TEAR STRAP WIDTH ONLY - TIME LIMITED SKIN REPAIR ............................................. 8 0 FIGURE 7: INSPECTION OF THE TIME-LIMITED SKIN REPAIR .................... 8 5 FIGURE 8: LOGIC DIAGRAM FOR OPERATIONAL INSPECTIONS OF THE TIME-LIMITED SKIN REPAIR .................................................. 8 6 FIGURE 9: FUSELAGE - STRINGER 4 TIME LIMITED SKIN REPAIR PERMANENT MODIFICATION . 87
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 3 of 247 BOEING SERVICE BULLETIN 737-53A1234
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FIGURE 10: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 2] .......... 9 7 FIGURE 11: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 1] ......... 1 0 0 FIGURE 12: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 2] ......... 1 0 3 FIGURE 13: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 3] ......... 1 0 6 FIGURE 14: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 4] ......... 1 0 9 FIGURE 15: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 3] ......... 1 1 2 FIGURE 16: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 1] ......... 1 1 5 FIGURE 17: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 2] ......... 1 1 8 FIGURE 18: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 3] ......... 1 2 1 FIGURE 19: FUSELAGE - CROWN AREA SKIN LAP JOINT INSPECTION [Group 4] ......... 1 2 4 FIGURE 20: FUSELAGE - CROWN AREA SKIN SHEAR WRINKLE INSPECTION [Group 1] ..... 1 2 7 FIGURE 21: FUSELAGE - CROWN AREA SKIN SHEAR WRINKLE INSPECTION [Group 2] ..... 1 3 1 FIGURE 22: FUSELAGE - CROWN AREA SKIN SHEAR WRINKLE INSPECTION [Group 3] ..... 1 3 5 FIGURE 23: FUSELAGE - CROWN AREA SKIN SHEAR WRINKLE INSPECTION [Group 4] ..... 1 3 9 FIGURE 24: FUSELAGE - CROWN AREA SKIN BUTT JOINT INSPECTION [Group 1] ........ 1 4 3 FIGURE 25: FUSELAGE - CROWN AREA SKIN BUTT JOINT INSPECTION [Group 2] ........ 1 4 7 FIGURE 26: FUSELAGE - CROWN AREA SKIN BUTT JOINT INSPECTION [Group 3] ........ 1 5 1 FIGURE 27: FUSELAGE - CROWN AREA SKIN BUTT JOINT INSPECTION [Group 4] ........ 1 5 5 FIGURE 28: FUSELAGE - CROWN AREA SKIN INSPECTION [Group 1] ................ 1 5 9 FIGURE 29: FUSELAGE - CROWN AREA SKIN INSPECTION [Group 2] ................ 1 6 3 FIGURE 30: FUSELAGE - CROWN AREA SKIN INSPECTION [Group 3] ................ 1 6 7 FIGURE 31: FUSELAGE - CROWN AREA SKIN INSPECTION [Group 3] ................ 1 7 1 FIGURE 32: FUSELAGE - CROWN AREA SKIN INSPECTION [Group 4] ................ 1 7 5 FIGURE 33: FUSELAGE - CROWN AREA SKIN INSPECTION ..................... 1 7 9 FIGURE 34: FUSELAGE - STRINGER 10 PERMANENT SKIN REPAIR ................ 1 8 2 FIGURE 35: FUSELAGE - STRINGER 4 - 3.88-4.30 INCH TEAR STRAP WIDTH ONLY - TIME LIMITED SKIN REPAIR ......................................... 1 9 3 FIGURE 36: FUSELAGE - STRINGER 10 - 3.0-3.54 INCH TEAR STRAP WIDTH ONLY - TIME LIMITED SKIN REPAIR ......................................... 1 9 8 FIGURE 37: FUSELAGE - STRINGER 10 TIME LIMITED SKIN REPAIR PERMANENT MODIFICATION ................................................. 2 0 3 FIGURE 38: FUSELAGE - STRINGER 4 INTERNAL TEAR STRAP DOUBLER INSTALLATION . . . 212 FIGURE 39: FUSELAGE - STRINGER 10 INTERNAL TEAR STRAP DOUBLER INSTALLATION . . 219 FIGURE 40: FUSELAGE - PERMANENT LAP JOINT REPAIR WITH INTERNAL TEAR STRAP DOUBLERS PART 26 INSPECTIONS ................................... 2 2 6 FIGURE 41: FUSELAGE - PERMANENT LAP JOINT REPAIR WITHOUT INTERNAL TEAR STRAP DOUBLERS PART 26 INSPECTIONS ............................ 2 2 8 APPENDIX A: SKIN DRAWINGS FOR CHEM-MILL POCKET LOCATIONS ............... 2 3 0 APPENDIX B: NDI INSPECTION DETAIL .................................. 2 4 7
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 4 of 247 BOEING SERVICE BULLETIN 737-53A1234
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1234Original Issue: June 13, 2002 Revision 2: November 24, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Cracks at Chem-milled Steps - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive 2005-13-27, is related to this service bulletin.
More work is necessary on airplanes inspected in accordance with the original issue and Revision 1 of this service bulletin. Additional areas have been identified to be inspected for horizontal chem-mill cracks and new inspections for vertical chem-mill cracks are now required. Previously repaired areas require additional repairs.
REASON FOR REVISION This revision is sent to add additional inspections for horizontal chem-mill cracks away from the lap joints over the entire crown, new inspections for vertical chem-mill cracks adjacent to the butt joints and adding internal tear strap doublers at the tear straps adjacent to existing permanent repairs.
The airplane effectivity is divided into 4 groups as follows:
Group 1 - 737-300 airplanes line number 2553 through 3132 excluding airplane variable numbers PS763-PS799, PS901-PS906. Group 2 - 737-300 airplanes with variable numbers PS763-PS799, PS901-PS906. Group 3 - 737-400 airplanes line number 2553 through 3132. Group 4 - 737-500 airplanes line number 2553 through 3132.
These sections were changed:
1. Paragraph 1.C.Reason - added more background information
2. Paragraph 1.D.Description - added more inspection information
3. Added maintenance zone tables
4. Paragraph 1.E.Compliance - added new compliance tables
5. Paragraph 1.F.Approval - added AD information
6. Paragraph 1.G.Manpower - adjusted Task-Hours
7. Paragraph 1.J.References - added NDT references and AD number
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 5 of 247
8. Paragraph 1.K.Publications Affected - added DTI statement
9. Paragraph 3.B. Work Instructions - added additional inspection information
10. Figure 1 - deleted and replaced by tables in Paragraph 1.E.Compliance
11. Figure 2 - Figure 4 - added new inspection areas
12. Figure 5, Figure 6, Figure 9 - updated repairs
13. Figure 7, Figure 8 - deleted and replaced by other figures
14. Figure 10 - Figure 19 - new crown skin lap joint inspections
15. Figure 20 - Figure 23 - new crown skin shear wrinkle inspections
16. Figure 24 - Figure 27 - new crown skin butt joint inspections
17. Figure 28 - Figure 33 - new crown area skin inspections
18. Figure 34 - Figure 39 - new repairs/modifications
19. Figure 40, Figure 41 - new part 26 inspections
20. Appendix A - reference for skin drawings
21. Appendix B - NDI inspection detail
22. Added a new effectivity group and modified group references throughout 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 June 13, 2002Original Issue:
March 31, 2005Revision 1:
November 24, 2010Revision 2:
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 6 of 247 BOEING SERVICE BULLETIN 737-53A1234
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1234Original Issue: June 13, 2002 Revision 2: November 24, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Cracks at Chem-milled Steps - 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 Accomplishment of the inspections and repairs shown in this service bulletin will ensure that fuselage skin cracks at specified locations are found and repaired. Continued operation with undetected skin cracks could cause unscheduled down time for repairs or possibly a decompression of the airplane.
Two operators have reported 77 horizontal chem-mill cracks just above the Stringer (S)-4 and S-10 lap joints on airplanes with 20 inch tear strap spacing. The airplanes had between 30,000 and 46,000 flight cycles at the time the cracks were discovered.
One operator has reported 9 cases of horizontal chem-mill cracking away from lap joint locations on 8 different airplanes with 20 inch tear strap spacing. These airplanes had between 37,000 and 45,000 total flight cycles at the time the cracks were discovered. It is believed that these horizontal chem-mill cracks in the crown skin at locations away from the lap joints occurred as a result of skin buckling during the normal flight spectrum combined with stress concentrations at the chem-mill step. As of the release date of this service bulletin there have not been any confirmed reports of cracks in the areas away from the lap joints that were not in the shear wrinkle areas, or areas next to filled in pockets as addressed in Service Bulletins 737-53A1301 or 737-53A1293. However, analysis and fleet data supporting service bulletin 737-53A1210 indicates that chem-mill cracking in these areas will also eventually occur as the airplanes accumulate more flight cycles.
Several cases of vertical chem-mill cracks have been reported adjacent to butt joints in airplanes covered by SB 737-53A1210. No vertical cracks have been reported by airplanes covered by this service bulletin but due to structural similarities and identical loading, additional inspections have now been added.
Analysis by Boeing indicates that these cracks are caused by fatigue due to high bending stresses at the edge of chem-milled steps.
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 7 of 247
ACTION On all affected airplanes, do Non Destructive Inspections (NDI) of the fuselage skin for cracks just above the S-4 and S-10 lap joints from STA 259.5 to STA 1016. Do NDI inspections for horizontal chem-mill cracks away from the lap joints in crown skin buckling areas over the entire crown skin. Do NDI inspections for vertical chem-mill cracks adjacent to the butt joints. Do NDI inspections for horizontal chem-mill cracks away from lap joints in general pocket-to-pocket crown skin areas that are not in a crown skin buckling area and that are not covered by 737-53A1301 R01 or 737-53A1293 R01 .
If cracks are found just above lap joints, repair before any more flights as shown in this service bulletin.
If cracks are found in areas other than the lap joints, contact Boeing for repair instructions and do the repair.
If no cracks are found, repeat inspection in accordance with Paragraph 1.E., Compliance .
EFFECTIVITY 737-300, -400, and -500 airplanes line numbers 2553 through 3132 in 4 groups. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive 2005-13-27 is related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release a new Airworthiness Directive related to this service bulletin. The new Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
The installation of a local (Time-Limited or Permanent) repair does not change the inspection requirements for the remaining non-repaired locations.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 8 of 247 BOEING SERVICE BULLETIN 737-53A1234
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BOEING SERVICE BULLETIN 737-53A1234
ALERT ALERT
DO NDI INSPECTIONS OF THE FUSELAGE SKIN FOR VERTICAL
CRACKS ALONG THE CHEM-MILL STEPS ADJACENT TO THE BUTT JOINTS. IF ANY CRACK IS FOUND, CONTACT BOEING FOR REPAIF
NSTRUCTIONS AND INSTALL THE REPAIR 00000000000 DO NDI INSPECTIONS OF THE por/000/0000 900000000000 FUSELAGE SKIN FOR HORIZONTAL CRACKS ALONG THE CHEM-MILL STEPS ADJACENT TO STRINGERS.
IF CRACKS ARE FOUND CONTACT
BOEING FOR REPAIR INSTRUCTIONS
AND INSTALL THE REPAIR
DO NDI INSPECTIONS OF THE SKIN FOR HORIZONTAL CRACKS *ACCORDANCE TH THE SERVICE BALLEN OR ASK BENE FOR REPAIR DATA AND DO THE REPAIR.
LEFT SIDE SHOWN
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 10 of 247 BOEING SERVICE BULLETIN 737-53A1234
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BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1234 Original Issue: June 13, 2002 Revision 2: November 24, 2010 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Cracks at Chem-milled Steps - 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 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 737-300 airplanes, line numbers 2553 through 3132 excluding airplane variable numbers PS763-PS799, PS901-PS906 -1 737-300 airplanes, variable numbers PS763-PS799, PS901-PS906-2 737-400 airplanes, line numbers 2553 through 3132-3 737-500 airplanes, line numbers 2553 through 3132-4 Airplane Models:
737-300, 737-400, 737-500 GroupVariable Number 3PJ552 - PJ561 3PJ601 - PJ615
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GroupVariable Number 3PJ811 3PJ816 - PJ817 1PM543 - PM550 1PP518 - PP520 1PP876 - PP877 1PQ297 - PQ299 1PQ345 - PQ348 1PQ370 - PQ373 1PQ391 - PQ395 1PQ408 - PQ410 1PQ414 - PQ418 1PQ431 - PQ438 1PQ447 - PQ448 1PQ451 1PQ454 1PQ473 - PQ475 1PQ772 1PQ933 - PQ935 1PQ951 1PQ971 - PQ997 1PR001 - PR017 1PR021 - PR034 1PR041 - PR045 1PR061 - PR072 1PR077 - PR082 1PR091 - PR092 1PR096 1PR101 1PR121 - PR122 1PR131 - PR132 1PR141 - PR143 1PR161 - PR172 1PR181
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Original Issue: June 13, 2002 737-53A1234Revision 2: November 24, 2010 12 of 247 BOEING SERVICE BULLETIN 737-53A1234