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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1248 Original Issue: September 09, 2004 Revision 2: October 14, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web - Inspection for Web Cracks at the Y-Chord 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 © 2004 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Unpublished Work.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: September 09, 2004 737-53A1248Revision 2: October 14, 2015 1 of 40
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 2 of 40 BOEING SERVICE BULLETIN 737-53A1248
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION11
A. Effectivity11
1. Airplanes11
2. Spares Affected17
B. Concurrent Requirements18
C. Reason18
D. Description18
E. Compliance19
F. Approval23
G. Manpower24
H. Weight and Balance Changes24
I. Electrical Load Data24
J. References24
1. Existing Data:24
2. Data Supplied with this Service Bulletin:25
3. Installation Drawings Used in the Preparation of this Service Bulletin:25
K. Publications Affected26
L. Interchangeability and Intermixability of Parts26
M. Software Accomplishment Summary26
2. MATERIAL INFORMATION27
A. Material - Price and Availability27
B. Industry Support Information27
C. Parts Necessary for Each Airplane27
1. Kits/Parts:27
2. Parts and Materials Supplied by the Operator:27
3. Parts Modified and Reidentified:27
4. Parts Removed and Not Replaced:27
D. Parts Necessary to Change Spares27
E. Special Tooling - Price and Availability27
F. Special Tooling Necessary to do this Service Bulletin27
3. ACCOMPLISHMENT INSTRUCTIONS29
A. GENERAL INFORMATION29
B. WORK INSTRUCTIONS30
FIGURE 1: LFEC AND DETAILED INSPECTION OF THE WEB AT THE "Y" CHORD - ABOVE S-15L AND
S-15R33
FIGURE 2: HFEC AND DETAILED INSPECTION OF THE WEB AT THE "Y" CHORD - ABOVE S-15L AND
S-15R36
FIGURE 3: HFEC, LFEC AND DETAILED INSPECTION OF WEB AT "Y" CHORD - BELOW S-15L AND
S-15R38
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 3 of 40 BOEING SERVICE BULLETIN 737-53A1248
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 4 of 40 BOEING SERVICE BULLETIN 737-53A1248
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1248Original Issue: September 09, 2004 Revision 2: October 14, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web - Inspection for Web Cracks at the Y-Chord This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes inspected in accordance with Revision 1 or the Original Issue of this service bulletin. Do repeat inspections in accordance with Paragraph 1.E., Compliance of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-21-06 is related to this service bulletin.
REASON FOR REVISION This revision is sent to change the repeat inspection intervals after the initial inspection threshold.
The data given in Alternative Method of Compliance Notice 737-53A1248 AMOC 01 is included in this revision.
These sections were changed:
1. Summary, Background - added Service Related Problem (SRP) reference, Widespread Fatigue Damage (WFD) statement, and Summary Evaluation table.
2. Summary, Action - revised inspection requirements to include corrosion as specified in AD 2005-21-06.
3. Summary, Compliance - added additional Airworthiness Directive statement, and added the effective date of AD 2005-21-06.
4. Paragraph 1.C., Reason - added SRP reference and AMOC incorporation statement.
5. Paragraph 1.D., Description - revised inspection requirements to include corrosion as specified in AD 2005-21-06, and added Affected Maintenance Zones table.
6. Paragraph 1.E., Compliance - added additional Airworthiness Directive statement, added the effective date of AD 2005-21-06, and revised the compliance table to change the repeat inspection intervals after the initial inspection threshold.
7. Paragraph 1.F., Approval - updated approval paragraphs.
8. Paragraph 1.G., Manpower - added footnote to Task Hour table.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 5 of 40
9. Paragraph 1.J., References - updated references.
10. Paragraph 1.K.2, Damage Tolerance Based Structural Inspections - added Damage Tolerance Inspections (DTI) statement.
11. Paragraph 3.A., General Information - added notes.
12. Paragraph 3.B., Work Instructions - revised inspection requirements to include corrosion as specified in AD 2005-21-06, reformatted instructions, and revised FIGURE 1 through FIGURE 3 Step Tables.
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 September 09, 2004Original Issue:
September 10, 2007Revision 1:
October 14, 2015Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 6 of 40 BOEING SERVICE BULLETIN 737-53A1248
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1248Original Issue: September 09, 2004 Revision 2: October 14, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web - Inspection for Web Cracks at the Y-Chord
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 the aft pressure bulkhead web on numerous 737-200/-300 airplanes inspected as shown in service bulletin 737-53A1214. In all of the cases, the cracks ran in the circumferential direction along the aft row of fasteners connecting the web assembly to the bulkhead "Y" chord. These cracks occurred in the S-6L and S-6R areas. The 737-600/700/700C/800/900 airplanes have a similar structure for the aft pressure bulkhead and could experience the same type of fatigue damage. If cracks are allowed to continue undetected the airplane could have an uncontrolled decompression.
The aft pressure bulkhead has been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
The Federal Aviation Administration (FAA) has issued Airworthiness Directive AD 2005-21-06 which requires incorporation of this service bulletin.
Boeing Service Related Problem (SRP) 737NG-SRP-53-0183 and 737NG-SRP-53-0473 are related to this service bulletin.
The data given in Alternative Method of Compliance Notice 737-53A1248 AMOC 01 is included in this revision.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 7 of 40
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance 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 aft side of the aft pressure bulkhead and do a Low Frequency Eddy Current (LFEC) and Detailed Inspection for circumferential cracks in the web where it attaches to the "Y" chord along the aft row of fasteners.
As an option to doing an inspection from the aft side of the bulkhead, it is acceptable to do a High Frequency Eddy Current (HFEC) and Detailed Inspection from the forward side of the bulkhead.
When performing an inspection from the aft side, if either a crack, crack indication, discrepant fastener hole, or corrosion is found, you must get access to the forward side of the bulkhead and do an HFEC and a Detailed Inspection to inspect for cracks from the forward side. Do the HFEC inspection for circumferential cracks along the aft row of fasteners at the "Y" chord for the section of web where the crack, crack indication, discrepant fastener hole, or corrosion was found. It is not necessary to do the HFEC inspection beyond the web splices of the web section containing the crack, crack indication, discrepant fastener hole, or corrosion. Do the Detailed Inspection for cracks in the web and for incorrectly drilled or elongated fastener holes. At the crack indication fastener location(s), remove the fastener(s) and do an HFEC open hole inspection. Refer to Maintenance Planning Document (MPD) section 9 for additional inspection requirements.
Repeat inspections may be performed from either the aft or forward side of the aft pressure bulkhead at the times indicated in Paragraph 1.E., Compliance.
If any crack, crack indication, discrepant fastener hole, or corrosion is found, repair before further flight.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 8 of 40 BOEING SERVICE BULLETIN 737-53A1248
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Contact The Boeing Company for repair instructions and do the repair.
NOTE: When contacting Boeing for repair instructions, give the size and location of the damage. When possible, send sketches and photographs. If the damage includes corrosion, send data on the length, width and largest depth of the clean up.
Send to:
BOEING COMMERCIAL AIRPLANES GROUP ATTENTION: MANAGER, AIRLINE SUPPORT
EFFECTIVITY 737-600/-700/-700C/-800/-900 airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE 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.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2005-21-06 is related to this service bulletin.
The effective date of AD 2005-21-06 is November 25, 2005.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection 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: September 09, 2004 737-53A1248Revision 2: October 14, 2015 9 of 40 BOEING SERVICE BULLETIN 737-53A1248
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BOEING SERVICE BULLETIN 737-53A1248
ALERT ALERT BL ACCESS DOOR 5-71- →S-7R S-15L - ~S-15R "Y" CHORD A-A
FRAME VIEW LOOKING FORWARD CHORD
- WEB
INSPECT THE WEB ALONG THE AFT ROW OF
FASTENERS AND ALONG THE EDGE OF THE "Y" CHORD USING EDDY CURRENT AND
VISUAL INSPECTION FWD B—B N71435 Original Issue: September 09, 2004 Revision 2: October 14, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1248 Work - See page 1 for details. 10 of 40
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1248 Original Issue: September 09, 2004 Revision 2: October 14, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Body Station 1016 Aft Pressure Bulkhead Web - Inspection for Web Cracks at the Y-Chord
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 This service bulletin is applicable to 737-600/-700/-700C/-800/-900 airplanes, line numbers 1 - 1755 in 1 Group(s). The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 737-600, -700, -700C, -800, -900 airplanes, line numbers 1 - 1755-1 Airplane Models:
737-600, 737-700, 737-700C, 737-800, 737-900 GroupVariable Number 1YA001 - YA099 1YA101 - YA199 1YA201 - YA211 1YA221 1YA231 - YA242 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 11 of 40
GroupVariable Number 1YA251 - YA256 1YA271 - YA272 1YA291 1YA301 - YA302 1YA311 - YA314 1YA321 - YA323 1YA336 - YA345 1YA351 1YA356 - YA357 1YA366 - YA367 1YA371 - YA377 1YA501 - YA536 1YA541 - YA552 1YA571 - YA578 1YA601 - YA615 1YA621 - YA622 1YA626 - YA631 1YA635 - YA636 1YA641 - YA642 1YA645 - YA650 1YA656 - YA659 1YA666 - YA667 1YA671 - YA672 1YA681 - YA691 1YA701 - YA710 1YA721 - YA722 1YA731 - YA734 1YA751 - YA756 1YA801 - YA803 1YA809 1YA811 - YA814 1YA831 - YA835 1YA841 - YA862 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: September 09, 2004 737-53A1248Revision 2: October 14, 2015 12 of 40 BOEING SERVICE BULLETIN 737-53A1248