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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1254 Original Issue: February 17, 2005 Revision 1: July 09, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Body Frame and Overwing Stub Beam Inspection and Repair - Body Stations 597 to 639 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2005 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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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Original Issue: February 17, 2005 737-53A1254Revision 1: July 09, 2009 1 of 147
3.0
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Original Issue: February 17, 2005 737-53A1254Revision 1: July 09, 2009 2 of 147 BOEING SERVICE BULLETIN 737-53A1254
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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 ........................................ 1 9 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 2 1 E. Compliance .............................................. 2 2 F . Approval ............................................... 2 8 G. Manpower .............................................. 2 9 H. Weight and Balance Changes .................................... 3 1 I. Electrical Load Data ......................................... 3 1 J. References .............................................. 3 1
1. Existing Data: .......................................... 3 1
2. Data supplied with this Service Bulletin: ........................... 3 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 3 K. Publications Affected ......................................... 3 3 L. Interchangeability and Intermixability of Parts ........................... 3 3
2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 B. Industry Support Information .................................... 3 6 C. Parts Necessary For Each Airplane ................................. 3 6
1. Kits/Parts: ............................................ 3 6
2. Parts and Materials Supplied by the Operator: ........................ 4 0
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 3 FIGURE 1: INSPECTION OF THE BS 616 AND BS 639 FRAMES FROM STRINGER S-15 TO THE LOWER END FRAME AND THE STUB BEAM (GROUP 1 AIRPLANES) ............... 5 0 FIGURE 2: INSPECTION OF THE BS 616 AND BS 639 FRAMES FROM STRINGER S-15 TO THE LOWER END FRAME AND THE STUB BEAM (GROUP 2 AIRPLANES) ............... 5 3 FIGURE 3: INSPECTION OF THE BS 616 AND BS 639 FRAMES FROM STRINGER S-15 TO THE LOWER END FRAME AND THE STUB BEAM (GROUP 3 AIRPLANES) ............... 5 6 FIGURE 4: INSPECTION OF THE FRAME INNER CHORD AT BS 616 - PREVENTIVE MODIFICATION INSTALLED ........................................... 5 9 FIGURE 5: INSPECTION OF THE FRAME INNER CHORD AT BS 616 - REPAIR INSTALLED .... 6 0 FIGURE 6: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES FROM STRINGER S-15 TO THE LOWER END FRAME AND THE STUB BEAM (GROUP 1 AIRPLANES) .......... 6 1
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FIGURE 7: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES FROM STRINGER S-15 TO THE LOWER END FRAME AND THE STUB BEAM (GROUP 2 AIRPLANES) .......... 6 7 FIGURE 8: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES FROM STRINGER S-15 TO THE LOWER END FRAME AND THE STUB BEAM (GROUP 3 AIRPLANES) .......... 7 3 FIGURE 9: INSPECTION OF THE LOWEST TWO FASTENERS COMMON TO THE INNER CHORD AT B S 6 0 1............................................. 7 8 FIGURE 10: INSPECTION OF THE SHEAR TIE CLIP AT BS 597 ..................... 8 0 FIGURE 11: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES FROM BETWEEN S-14 AND S-15 TO THE LOWER END (GROUP 1 AIRPLANES) .................... 8 3 FIGURE 12: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES FROM BETWEEN S-14 AND S-15 TO THE LOWER END (GROUP 2 AIRPLANES) .................... 8 6 FIGURE 13: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES FROM BETWEEN S-14 AND S-15 TO THE LOWER END (GROUP 3 AIRPLANES) .................... 8 9 FIGURE 14: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES FROM BETWEEN S-14 AND S-15 TO THE LOWER END (GROUP 1 AIRPLANES) .................... 9 2 FIGURE 15: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES FROM BETWEEN S-14 AND S-15 TO THE LOWER END (GROUP 2 AIRPLANES) .................... 9 5 FIGURE 16: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES FROM BETWEEN S-14 AND S-15 TO THE LOWER END (GROUP 3 AIRPLANES) .................... 9 8 FIGURE 17: PREVENTATIVE MODIFICATION OF THE FRAME INNER CHORD AT BS 601 (GROUP 3 AIRPLANES) ......................................... 1 0 1 FIGURE 18: REPAIR OF THE FRAME INNER CHORD AT BS 616 AND BS 639 (GROUP 1 AIRPLANES) ................................................. 1 0 5 FIGURE 19: REPAIR OF THE FRAME INNER CHORD AT BS 616 AND BS 639 (GROUP 2 AIRPLANES) ................................................. 1 1 2 FIGURE 20: REPAIR OF THE FRAME INNER CHORD AT BS 601, BS 616 AND BS 639 (GROUP 3 AIRPLANES) ......................................... 1 1 9 FIGURE 21: FABRICATION INSTRUCTIONS - FILLER .......................... 1 2 8 FIGURE 22: FABRICATION INSTRUCTIONS - STIFFENING ANGLE .................. 1 3 0 FIGURE 23: FABRICATION INSTRUCTIONS - TAPERED SHIM ..................... 1 3 2 FIGURE 24: BS 616 AND BS 639 FRAME POST -REPLACEMENT INSPECTION FOR SSID ITEM F-20 ................................................. 1 3 4 FIGURE 25: DETAILED INSPECTION OF THE FRAME INNER CHORD AT BS 616 AND BS 639 - REPAIR OR PREVENTIVE MODIFICATION INSTALLED ...................... 1 3 8 FIGURE 26: HFEC INSPECTION OF THE FRAME INNER CHORD AT BS 616 AND BS 639 - REPAIR OR PREVENTIVE MODIFICATION INSTALLED......................... 1 4 2 Appendix A: INSPECTION REPORT FORM ................................ 1 4 6
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Original Issue: February 17, 2005 737-53A1254Revision 1: July 09, 2009 4 of 147 BOEING SERVICE BULLETIN 737-53A1254
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1254Original Issue: February 17, 2005 Revision 1: July 09, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Body Frame and Overwing Stub Beam Inspection and Repair - Body Stations 597 to 639 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on airplanes inspected as given in the original issue of this service bulletin. Additional inspections for cracks to the stub beam at BS 616 and BS 639, cracks to the frame inner chord at BS 601 and cracks at the frame shear ties of BS 597 are necessary.
737-200C series airplanes PY056-PY057, PY409-PY410, PY422, PY463, PY591-PY595, PY671-PY672, PY721, PY741 are removed from Group 1 of the service bulletin effectivity.
REASON FOR REVISION This revision is sent to include a partial frame replacement of the lower frame section below S-14 at BS 616 and BS 639, a frame inner chord repair common to the lower two fastener holes at BS 601, BS 616 and BS 639, a preventive modification of the lower end frame inner chord at BS 601, an inspection of the stub beam at BS 616 and 639 for cracking and an inspection at BS 597 for cracking to the frame shear ties.
All 737-200C series airplanes are removed from the effectivity of this service bulletin because they have a different frame and stub beam configuration that is not susceptible to the type of cracking defined in this service bulletin. There have been no fleet reports of cracking at BS 597, BS 616 and BS 639 on 737-200C airplanes.
These sections were changed:
1. Summary: The BACKGROUND, ACTION, MANPOWER and MATERIAL INFORMATION sections are updated.
2. Paragraph 1.A., Effectivity: All 737-200C series airplanes are removed from effectivity.
3. Paragraph 1.C., Reason: Reasons for additional inspections are given.
4. Paragraph 1.D., Description: Information is added for repair to BS 601, BS 616 and BS 639 and preventive modification to BS 601. Information is also added for the shear ties inspection at BS 597, frame inner chord inspection at BS 601, and the stub beam inspection at BS 616 and BS 639. Maintenance zone data is added.
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5. Paragraph 1.E., Compliance: Compliance information is added for BS 616 and BS 639 partial frame splice repairs and additional inspections at BS 597 and BS 601. Also compliance information for BS 601 preventive modification and BS 601, BS 616 and BS 639 lower end frame inner chord repair is included.
6. Paragraph 1.G., Manpower: Manpower estimates are revised for inspections to BS 616 and BS 639 frame inner chord, outer chord and web inspection, stub beam inspection, frame inner chord lower section repair, and partial frame replacement. Manpower estimates are also added for BS 601 lower frame inner chord inspection, preventive modification and repair, and BS 597 frame shear ties inspection.
7. Paragraph 1.H., Weight and Balance Changes: New weight and moment changes are added.
8. Paragraph 2.A., Material - Price and Availability: New parts are added.
9. Paragraph 2.C., Parts Necessary For Each Airplane: New parts added in Kits/Parts and Parts and Materials Supplied by the Operator.
10. Paragraph 3.A., General Information: General Information notes are updated.
11. Paragraph 3.B., Work Instructions: Work Instructions are added for inspections to the shear tie clips at BS 597, frame inner chord lower end inspection at BS 601 and frame inner chord, outer chord, web and stub beam inspection at BS 616 and BS 639. Instructions are also added for BS 601 frame inner chord lower end section preventive modification and repair, BS 616 and BS 639 frame inner chord lower end section repair and partial frame replacement.
12. Figures: New Figures 6 to 26 are added to this revision for inspections to the shear tie clips at BS 597, lower end frame inspection, preventive modification and repair at BS 601, BS 616 and BS 639 and a lower partial frame splice repair at BS 616 and BS 639. Instructions are also added for the inspection of the stub beam at BS 616 and BS 639.
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.
The data given in Information Notice 737-53A1254 IN 01 is not included in this revision. IN 01 was sent to advise operators that the date on the original issue of the service bulletin was not the correct issue date of the service bulletin. Due to changes to the compliance data in Revision 1 of this service bulletin, the information in IN01 is no longer relevant.
REVISION HISTORY February 17, 2005Original Issue:
July 09, 2009Revision 1:
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Original Issue: February 17, 2005 737-53A1254Revision 1: July 09, 2009 6 of 147 BOEING SERVICE BULLETIN 737-53A1254
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1254Original Issue: February 17, 2005 Revision 1: July 09, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Body Frame and Overwing Stub Beam Inspection and Repair - Body Stations 597 to 639
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 The cause of the cracks at BS 616 and BS 639 frame sections below S-15 is due to fatigue. This fatigue failure is due to high flight cycle stresses from both pressurization and maneuver load.
After the release of the original issue of this service bulletin, there were 25 fleet reports of frame cracking in BS 601 or BS 597 along with stub beam cracking in BS 616 and BS 639.
Service Bulletin 737-53-1182 is used to inspect for cracks emanating from the frame inner chord lower end fastener hole located at BS 616 and BS 639. This service bulletin expands upon the inspection area shown in service bulletin 737-53-1182 and identifies several new locations for possible cracks. The airplane effectivity for this service bulletin includes all airplanes listed in the effectivity for service bulletin 737-53-1182 and additional airplanes that also need to be inspected. This service bulletin supersedes service bulletin 737-53-1182.
Periodic inspections of the body frame from between the stringer S-15 and stringer S-16 to the bottom tip of the frame, frame inner chord lower end fastener holes, frame shear ties and stub beam structure at Body Stations 616, 639 and 597 or 601 as given in this service bulletin will detect cracks at an early stage of propagation. The accomplishment of a repair or preventive modification will reduce the possibility of undetected fatigue cracks which could result in severed frames and induce skin cracks at these locations. This could lead to rapid decompression of the fuselage.
Boeing Service Related Problem (SRP) 737-SRP-53-0182 is related to this service bulletin.
ACTION (PRR 35005-281RS) The airplane effectivity is divided into 3 groups based on stub beam configuration. Group 1 is 737-200 passenger airplanes, Group 2 is 737-300 and -500 passenger airplanes and Group 3 is 737-400 passenger airplanes.
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Remove seats, carpets, side panels and floor panels to get access to the overwing stub beams and body frames at Body Stations 616, 639, 597 or 601.
Do a detailed inspection to detect cracks in the BS 616 and BS 639 frame web, inner chord and outer chord from three fastener rows above S-16 to the lower end of the frames and the stub beam assembly from BL 45.5 to the outboard end. As an option to the detailed inspection, do a HFEC inspection of the BS 616 and BS 639 frame inner chord, outer chord and web from three fastener rows above S-16 down to the lower end of the frames and the stub beam assembly for cracks. If cracking is found in the frame outside of the lowest two fastener holes of the inner chord, do a detailed inspection of the crease beam inboard chord for cracking. If no cracking is found on the crease beam, do a partial frame replacement of the lower frame section as detailed in this service bulletin. If cracks are found in the inner chord common to the lowest two fastener holes and cracks are within allowable damage, repair as detailed in this service bulletin. If cracking is found on the stub beam or in the frame that is outside the limits of this service bulletin, contact Boeing for repair instruction.
Group 3: Do a detailed inspection of the inner chord common to the lowest two fastener holes at BS 601 for cracks. As an option to the detailed inspection, do a HFEC inspection of the BS 601 inner chord common to the two lowest fastener holes for cracks. If cracks are found and are within the limits defined in this service bulletin, accomplish the repair as detailed in this service bulletin. If cracks are found outside the limit defined in this service bulletin, contact Boeing for repair instructions and do the repair. If no cracks are found, a preventive modification stiffening angle can be accomplished as detailed in this service bulletin or continue the inspections.
Group 1-2: At BS 597 do a detail inspection of the frame shear ties for cracks. If cracks are found, contact Boeing for repair instructions and do the repair.
The BS 616 and BS 639 frames inner and outer chords between S-9 and S-16 are part of Structural Significant Item (SSI) F-20. The partial frame replacement requires the installation of the needed splice angles and straps between S-14 and S-15. The splice angles and strap hinders the SSI F-20 inspection requirements. Alternate inspection methods are provided in this service bulletin for the locations where the repair covers the SSI area.
For airplanes where the service bulletin 737-53-1182 R1 repair or preventive modification has been installed at BS 616 and BS 639, alternate inspections are provided.
Do the detailed or HFEC inspections at the thresholds given in the compliance section of this service bulletin.
If no cracks are found, repeat the detailed or HFEC inspections at the intervals for the appropriate method as given in the compliance section of this service bulletin. Record the results of all crack inspections on the form in Appendix A of this service bulletin.
EFFECTIVITY 737-200 airplanes from line number 849 through 1585 and 737-300,-400,-500 airplanes from line number 1001 through 3132.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an 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 Directives (AD) 98-11-04 R01 and 2008-09-13 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
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Original Issue: February 17, 2005 737-53A1254Revision 1: July 09, 2009 8 of 147 BOEING SERVICE BULLETIN 737-53A1254
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INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, repair and modification procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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Original Issue: February 17, 2005 737-53A1254Revision 1: July 09, 2009 9 of 147 BOEING SERVICE BULLETIN 737-53A1254
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BOEING SERVICE BULLETIN 737-53A1254
ALERT ALERT ESCAPE HATCH BS ANK UPPER SURFAC FUEL 639 BS S-16 616 BBL BODY FRAME 45.5
SKIN INNER CHORD
• FWD
STRINGER
CLIP INSPECT
FOR CRACKS S-16 -
CREASE BEAM BODY
FRAME INSPECT OUTER CHORD 208 WL FOR CRACKS UPPER CHORD STUB BEAM FRAME > INBD
FRAME TIE STUB BEAM
FITTING LOWER CHORD BBL
45.5 BBL 70.85 STUB CENTER WING FUEL
UPPERCHORD BEAM TANK UPPER SURFACE A-A REAR VIEW OF BODY STATION 639 FOR A GROUP 1 AIRPLANE SHOWN, BODY STATION 616 SIMILAR.
Original Issue: February 17, 2005 Revision 1: July 09, 2009 737-53A1254
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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1254 Original Issue: February 17, 2005 Revision 1: July 09, 2009 ATA System: 5311 SUBJECT: FUSELAGE - Body Frame and Overwing Stub Beam Inspection and Repair - Body Stations 597 to 639
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 Groups are based on stub beam configuration. 737-200 passenger airplanes from line number 849 to 1585 with BS 597, BS 616 and BS
639.
-1 Groups are based on stub beam configuration. 737-300 and 737-500 passenger airplanes from line number 1001 to 3130 with BS 597, BS 616 and BS 639.
-2 Groups are based on stub beam configuration. 737-400 from line number 1487 to 3132 with BS 601, BS 616 and BS 639.
-3 Airplane Models:
737-200, 737-300, 737-400, 737-500
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GroupVariable Number 1PJ119 3PJ301 - PJ302 3PJ551 - PJ561 3PJ601 - PJ615 3PJ811 3PJ816 - PJ817 1PK216 - PK220 1PK274 1PK361 1PK504 1PK515 1PK519 1PK525 - PK528 1PK560 1PK564 - PK565 1PK610 1PK617 1PK630 - PK637 1PK663 - PK666 1PK679 - PK681 1PK696 - PK697 1PK750 - PK765 1PK801 - PK804 1PK827 1PK933 - PK938 1PL023 - PL028 1PL111 - PL113 1PL172 1PL221 1PL412 - PL417 1PL455 - PL456 1PL560 - PL562
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