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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1204 Original Issue: June 19, 2003 Revision 2: June 24, 2010 ATA System: 5311 SUBJECT: FUSELAGE - Main Frame - Frames and Bulkheads - Body Station BS 360 - BS 348.2 and BS 303.9 - BS 294.5 Stringers S-7L - S-16L Left Intercostal Inspection / Repair / Modification 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
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4.0
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Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 6 B. Concurrent Requirements ...................................... 2 6 C. Reason ................................................ 2 7 D. Description .............................................. 2 7 E. Compliance .............................................. 2 9 F. Approval ............................................... 3 6 G. Manpower .............................................. 3 6 H. Weight and Balance Changes .................................... 3 8 I. Electrical Load Data ......................................... 3 8 J. References .............................................. 3 8
1. Existing Data: ......................................... 3 8
2. Data supplied with this Service Bulletin: ........................... 3 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 9 K. Publications Affected ........................................ 3 9 L. Interchangeability and Intermixability of Parts ........................... 3 9
2. MATERIAL INFORMATION ........................................ 4 1 A. Material - Price and Availability ................................... 4 1 B. Industry Support Information .................................... 4 1 C. Parts Necessary For Each Airplane ................................. 4 1
1. Kits/Parts: ........................................... 4 1
2. Parts and Materials Supplied by the Operator: ........................ 4 1
3. Parts Modified and Reidentified: ............................... 4 1
4. Parts Removed and Not Replaced: .............................. 4 1 D. Parts Necessary to Change Spares ................................. 4 1 E. Special Tooling - Price and Availability ............................... 4 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 3 A. GENERAL INFORMATION ..................................... 4 3 B. WORK INSTRUCTIONS ....................................... 4 4 FIGURE 1: INTERCOSTAL WEB, ATTACHMENT CLIPS, STRAP AND STRINGER SPLICE CHANNEL -
PASSENGER AIRPLANES THAT ARE PREVIOUSLY NOT REPAIRED PER SRM - INSPECTION [Group 1, 3] ........................................... 5 0 FIGURE 2: INTERCOSTAL WEB, ATTACHMENT CLIPS, STRAP, STRINGER SPLICE AND STRINGER REINFORCEMENT AUX INTERCOSTAL - PASSENGER AIRPLANES - INSPECTION [Group 1 , 3 ] ............................................... 5 3 FIGURE 3: INTERCOSTAL WEB, ATTACHMENT CLIP, STRAP AND STRINGER - CARGO AIRPLANES
- INSPECTION [Group 2] ................................... 5 9 FIGURE 4: REPAIRED INTERCOSTAL WEB, ATTACHMENT CLIPS, STRINGER SPLICE CHANNEL, REPAIRED TEE, AND STRAP - PASSENGER AIRPLANES - INSPECTION [Group 1, 3] . 66 FIGURE 5: INTERCOSTAL WEB, ATTACHMENT CLIP AND STRAP - PASSENGER AIRPLANES AND NOT PREVIOUSLY REPAIRED PER SRM - INSPECTION [Group 4] ........... 6 9
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FIGURE 6: REPAIRED INTERCOSTAL WEB, ATTACHMENT CLIPS, TEE AND STRAP - PASSENGER AIRPLANES - INSPECTION [Group 4] ............................ 7 2 FIGURE 7: INTERCOSTAL WEB, ATTACHMENT CLIPS, STRAP, AND STRINGER REINFORCEMENT AUX INTERCOSTAL - PASSENGER AIRPLANES - INSPECTION [Group 4] ....... 7 5
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1204Original Issue: June 19, 2003 Revision 2: June 24, 2010 ATA System: 5311 SUBJECT: FUSELAGE - Main Frame - Frames and Bulkheads - Body Station BS 360 - BS 348.2 and BS 303.9 - BS 294.5 Stringers S-7L - S-16L Left Intercostal Inspection / Repair / Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes changed in accordance with Revision 1 of this service bulletin.
The more work is necessary on airplanes changed in accordance with Revision 1 of this service bulletin to include inspection of cargo barrier net fitting at S-15L lower door stop intercostal between BS 348.2 and BS
360.
REASON FOR REVISION This revision is sent to update the compliance info and inspection instructions on the intercostals as well as parts replacement and repair instructions if cracks are found at S-14L, S-15L and S-16L intercostals. In addition, an additional inspection of the S-15L aft intercostal from BS 348.2 to BS 360 for -200C airplanes was added.
These sections were changed:
1. In Paragraph 1.A.1., Airplanes, Group 1 airplanes listed in Revision 1 is split into Group 1, Group 3 and Group 4.
2. In Paragraph 1.D., Description, revised as follows:
a. Added Group 3 and Group 4 passenger airplanes.
b. Added more work statement.
c. Added Maintenance Zone Tables.
3. In Paragraph 1.E., Compliance, revised as follows:
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a. Formatting changes.
b. Added inspection of S-15L from BS 348.2 to BS 360 for Group 2 airplanes.
c. Added compliance information for repairs of S-14L, S-15L and S-16L intercostals from BS 348.2 to BS 360 in Group 1 and 3 airplanes.
d. Additional tables were added for Group 4 airplanes.
4. In Paragraph 1.G., Manpower, changed table as follows:
a. Removed repair of S-16L intercostal.
b. Added for changes made per Figures 3.
5. In Paragraph 1.J., References, added Federal Aviation Administration (FAA) Airworthiness Directive 2009-16-14.
6. In Paragraph 1.K., Publications, added as follows:
a. Changed in accordance with information notice IN01.
b. Added damage tolerance information.
7. In Paragraph 2.B., Industry Support Information, changed statement.
8. In Paragraph 3.B., Work Instructions, revised as follows:
a. Revised to redirect work to SB 737-53A1240 R1 if cracks are found in S-16L door stop intercostal between BS 351.2 through BS 360 for Group 1 and Group 3 airplanes.
b. Revised to redirect work to SB 737-53A1240 R1 if cracks are found in S-14L, S-15L door stop intercostal aft of BS 348.2 frame and S-16L door stop intercostal from BS 348.2 to BS 351.2 for Group 1 and Group 3 airplanes.
c. Added note that Structural Repair Manual (SRM) repairs of cracks found in S-16L intercostal are obsolete and can no longer be used for new repairs.
d. Added inspection requirement for S-15L intercostal for cargo airplanes.
e. Group 1 of revision 1 was divided into Group 1, Group 3 and Group 4.
9. Figure 2, added S-15L inspection requirement.
10. Figure 3, added for Cargo Inspections, was Figure 2.
11. Figures 4 through 7, added for clarification.
12. The data given in Information Notice (IN) 737-53A1204 R01 IN02 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
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Pages with no vertical lines have no important changes.
REVISION HISTORY June 19, 2003Original Issue:
March 26, 2007Revision 1:
June 24, 2010Revision 2:
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1204Original Issue: June 19, 2003 Revision 2: June 24, 2010 ATA System: 5311 SUBJECT: FUSELAGE - Main Frame - Frames and Bulkheads - Body Station BS 360 - BS 348.2 and BS 303.9 - BS 294.5 Stringers S-7L - S-16L Left Intercostal Inspection / Repair / Modification
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 Refer to Paragraph 1.B., Concurrent Requirements.
BACKGROUND Several operators have reported airplanes with fatigue cracks in the intercostals on the forward and aft side of the forward entry door. The cracks are caused by fatigue from pressure loads applied at door stop fittings.
Incorporation of this service bulletin will prevent a possible decompression and unscheduled down time.
Prior to the original release of this service bulletin, eleven operators had reported airplanes with fatigue cracks in the intercostal web at body station (BS) 358.5 and stringer S-16L. The cracks extend from the inboard edge of the intercostal through tooling or fastener holes and terminate at the 2.0 inch diameter lightening hole. Three operators had reported four airplanes with cracks in intercostals at S-11L, S-12L and S-13L on the forward and aft side of the forward entry door. All additional cracks were in the radius of return flanges of the webs and attachment clips. One operator had reported one airplane with cracks in the stringer splice channels at S-14L and S-15L on the aft side of the forward entry door. The cracks were in the intercostal web attachment flange at the aft end of the intercostal.
Since the original release of this service bulletin, many operators have reported over one hundred cracks. Cracks have been found at all doorstop and hinge support intercostals on both the forward and aft side of the forward entry door. Operators have also reported cracks on several airplanes at multiple intercostal locations.
The Federal Aviation Administration (FAA) has issued Airworthiness Directive (AD) 2009-16-14 which requires incorporation of this service bulletin.
Boeing Structural Item Interim Advisory (SIIA) 737-183 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-53-0266 is related to this service bulletin.
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ACTION (PRR 35005-288R) The airplane effectivity is divided in four groups. Group 1, Group 3 and Group 4 are for passenger airplanes and Group 2 is for cargo airplanes.
Group 1, Group 3 and Group 4 airplanes are divided to differentiate the stringer connection at station 360 and intercostal configurations at hinge supports for the forward entry door. Group 1 and Group 3 airplanes have similar stringer splice configuration at station 360 fuselage production section joint. Group 4 airplanes have the stringer tie fitting configuration at station 360 production section joint. Group 1 and group 4 have the same similar intercostal at door hinge supports and Group 3 airplanes have the later intercostal configuration at door hinge supports. Group 2 are cargo airplanes and also have different intercostals at door hinge supports.
For Groups 1-4 airplanes gain access to stringer S-7L - S-16L intercostals forward of the forward entry door cutout (between BS 294.5 and BS 303.9) and aft of the forward entry door cutout (between BS 348.2 and BS
360).
Inspect the intercostal webs, attachment clips, straps, stringer reinforcement angle and stringer splice channels for cracks. Refer to Accomplishment Instructions Part 1 and Part 2 for Group 1 and Group 3 passenger airplanes, refer to Accomplishment Instructions Part 3 for Group 2 cargo airplanes, and refer to Accomplishment Instructions Part 4 and Part 5 for Group 4 passenger airplanes.
For Group 1 and Group 3 passenger airplanes, if cracks are found at S-14L, S-15L and S-16L intercostal between BS 348.2 and BS 360, do the repair in accordance with accomplishment instruction 3.B. of this service bulletin.
For group 1 and group 3 airplanes, if crack or damage is found at any other intercostal or the crack location is not covered by the repairs in accordance with SB 737-53A1240, Revision 1 contact Boeing for repair instructions and do the repair.
For Group 2 cargo airplanes, if cracks are found, contact Boeing for repair instruction and do the repair.
For Group 4 passenger airplanes, if cracks are found, contact Boeing for repair instructions.
EFFECTIVITY 737-100/200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.
COMPLIANCE See Section 1.E. Compliance for Boeing recommended compliance times and inspection intervals.
Federal Aviation Administration (FAA) Airworthiness Directive 2009-16-14, is related to this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections given in this service bulletin.
MANPOWER See table in Section 1.G. Manpower for man-hour estimate.
MATERIAL INFORMATION None.
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BOEING SERVICE BULLETIN 737-53A1204
ALERT ALERT
FORWARD ENTRY DOOR S-7L S-16L > S-7L DOOR FRAME
BS AREA
351.20 BS 360
INTERCOSTAL
BS WEB
351.20 BS
303.9 S-16L
294.5 BS 277 BS BS TYPICAL CRACK
259.5 LAND BS 360 SKIN
• STRAP STRINGER S-16L
CLIP FRAME
TYPICAL CRACKS-
ADDTIONAL CRACKS ARE IN
BEND RADIUS OF RETURN
FLANGES OF THE WEBS AND
TOOLING ATTACHMENT CLIPS HOLE
TYPICAL CRACK INSPECT INTERCOSTALS AT S-7L THRU S-16L
AROUND THE FORWARD ENTRY DOOR AND AT BS 348.2 TO BS 360 AT BS 294.5 TO BS 303.9 V83943 Original Issue: June 19, 2003 Revision 2: June 24, 2010 737-53A1204
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