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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1254 Original Issue: February 17, 2005 Revision 3: November 13, 2017 ATA System: 5310 5710 SUBJECT: FUSELAGE - Frame and Overwing Stub Beam at Body Stations 616, 639 and 597 or 601 - Buttock Line 45.5 Floor Beam Web at Body Station 639 - 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 © 2005 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Unpublished Work.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: February 17, 2005 737-53A1254Revision 3: November 13, 2017 1 of 192
4.0
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Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 2 of 192 BOEING SERVICE BULLETIN 737-53A1254
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary11
1. PLANNING INFORMATION15
A. Effectivity15
1. Airplanes15
2. Spares Affected23
B. Concurrent Requirements23
C. Reason23
D. Description25
E. Compliance27
F. Approval45
G. Manpower46
H. Weight and Balance Changes49
I. Electrical Load Data49
J. References49
1. Existing Data:49
2. Data Supplied with this Service Bulletin:50
3. Installation Drawings Used in the Preparation of this Service Bulletin:51
K. Publications Affected51
L. Interchangeability and Intermixability of Parts52
M. Software Accomplishment Summary52
2. MATERIAL INFORMATION53
A. Material - Price and Availability53
B. Industry Support Information55
C. Parts Necessary for Each Airplane55
1. Kits/Parts:55
2. Parts and Materials Supplied by the Operator:58
3. Parts Modified and Reidentified:59
4. Parts Removed and Not Replaced:59
D. Parts Necessary to Change Spares59
E. Special Tooling - Price and Availability59
F. Special Tooling Necessary to do this Service Bulletin60
3. ACCOMPLISHMENT INSTRUCTIONS61
A. GENERAL INFORMATION61
B. WORK INSTRUCTIONS62
FIGURE 1: INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group
1]75
FIGURE 2: INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group
2]78
FIGURE 3: INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15 [Group
3]81
FIGURE 4: DELETED AT REVISION 184
FIGURE 5: DELETED AT REVISION 185
FIGURE 6: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15
[Group 1]86
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FIGURE 7: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15
[Group 2]94
FIGURE 8: HFEC INSPECTION OF THE BS 616 AND BS 639 FRAMES AND STUB BEAMS BELOW S-15
[Group 3]102
FIGURE 9: INSPECTION OF THE LOWEST FOUR FASTENERS COMMON TO THE INNER CHORD AT
BS 601 [Group 3]108
FIGURE 10: INSPECTION OF THE SHEAR TIE S AT BS 597 [Group 1-2]110
FIGURE 11: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES BELOW S-14 [Group 1] . 113 FIGURE 12: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES BELOW S-14 [Group 2] . 116 FIGURE 13: PARTIAL FRAME REPLACEMENT OF THE BS 616 FRAMES BELOW S-14 [Group 3] . 119 FIGURE 14: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES BELOW S-14 [Group 1] . 122 FIGURE 15: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES BELOW S-14 [Group 2] . 125 FIGURE 16: PARTIAL FRAME REPLACEMENT OF THE BS 639 FRAMES BELOW S-14 [Group 3] . 128 FIGURE 17: PREVENTIVE MODIFICATION OF THE FRAME INNER CHORD AT BS 601 [Group 3] . 131
FIGURE 18: REPAIR OF THE FRAME INNER CHORD AT BS 616 AND BS 639 [Group 1]135
FIGURE 19: REPAIR OF THE FRAME INNER CHORD AT BS 616 AND BS 639 [Group 2]142
FIGURE 20: REPAIR OF THE FRAME INNER CHORD AT BS 601, BS 616 AND BS 639 [Group 3] . 149
FIGURE 21: FABRICATION INSTRUCTIONS - FILLER158
FIGURE 22: FABRICATION INSTRUCTIONS - STIFFENING ANGLE160
FIGURE 23: FABRICATION INSTRUCTIONS - TAPERED SHIM162
FIGURE 24: BS 616 AND BS 639 FRAME POST-REPLACEMENT INSPECTION FOR SSID ITEM F-20
.164
FIGURE 25: DETAILED INSPECTION OF THE FRAME INNER CHORD AT BS 616 AND BS 639 - REPAIR
OR PREVENTIVE MODIFICATION INSTALLED168
FIGURE 26: HFEC INSPECTION OF THE FRAME INNER CHORD AT BS 616 AND BS 639 - REPAIR OR
PREVENTIVE MODIFICATION INSTALLED171
FIGURE 27: INSPECTION OF THE WEB SPLICE AT BS 616 AND BS 639 - PARTIAL FRAME
REPLACEMENT INSTALLED174
FIGURE 28: OPEN HOLE HFEC INSPECTION AND HFEC SURFACE INSPECTION OF THE BL 45.5 LONGITUDINAL FLOOR BEAM WEB AT BS 639 STUB BEAM ATTACHMENT [Group 1-2]
.184
FIGURE 29: INSPECTION OF THE BS 616 MACHINED STUB BEAM UPPER CHORD [Group 2-3] . 187
Appendix A: INSPECTION REPORT FORM190
APPENDIX B: PART DEMAND INTENT192
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Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 4 of 192 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 3: November 13, 2017 ATA System: 5310 5710 SUBJECT: FUSELAGE - Frame and Overwing Stub Beam at Body Stations 616, 639 and 597 or 601 - Buttock Line 45.5 Floor Beam Web at Body Station 639 - Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-25-06 is related to this service bulletin.
Effects of this Revision on airplanes on which the original issue, Revision 1, or Revision 2 was previously done:
ActionConditionGroup Additional inspections for any crack to the stub beam at Body Station (BS) 616 and BS 639, any crack to the frame inner chord at BS 601 and any crack at the frame shear tie of BS 597 are necessary.
Airplanes on which the original issue was previously done.
All Airplanes that have removed and replaced certain stub beam to Buttock Line (BL) 45.5 longitudinal floor beam attachment angles require additional inspections of the replacement attachment angle. Additional fastener inspections and partial frame replacement inspections have also been added.
Airplanes on which Revision 1 was previously done.
All Inspect the BL 45.5 longitudinal floor beam at BS 639 for any crack.
Airplanes on which Revision 2 was previously done.
1 Inspect the BL 45.5 longitudinal floor beam at BS 639 for any crack and inspect the BS 616 stub beam upper chord for any crack.
Airplanes on which Revision 2 was previously done.
2 Inspect the BS 616 stub beam upper chord for any crack.
Airplanes on which Revision 2 was previously done.
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Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 5 of 192
REASON FOR REVISION This revision is sent to incorporate Alternative Method of Compliance Notice 737-53A1254-AMOC-03, to add a requirement for Group 1 and Group 2 airplanes to inspect the BL 45.5 longitudinal floor beam web at the BS 639 stub beam attachment, to provide a Structural Repair Manual (SRM) repair of the BL 45.5 longitudinal floor beam web at BS 639 for Group 2 airplanes and to clarify that inspection is required of the frame outer chord where a partial frame replacement is installed at BS 616 and BS 639. This revision also adds an inspection of the BS 616 stub beam upper chord.
The data given in Alternative Method of Compliance Notice 737-53A1254-AMOC-03 is included in this revision.
These sections were changed:
1. Service Bulletin ATA System and Subject, changed to add new inspection area, and clarify frame and stub beam locations.
2. Summary, Background, added new inspection area, Service Related Problem reference, Fleet Team Digest reference and acronym definitions.
3. Summary, Action, updated layout of existing and new action descriptions using common airplane grouping. Removed corrective action descriptions and removed statement describing alternate Structural Significant Item (SSI) F-20 inspections methods after partial frame replacement is done. Removed alternate inspections statement for airplanes with service bulletin 737-53-1182 R1 repair or preventive modification. Replaced "More work" statement from Revision 1 with an "Effects of this Revision" table.
4. Summary, Action, Description, Paragraph 1.E, Compliance, Paragraph 3.B, Work Instructions, Figures 1 through 3, 6 through 20 and 24 through 27, where instructions tell the operator to 'inspect for cracks' or 'inspect for cracking', the terminology is changed to 'inspect for any crack'.
5. Summary Effectivity, replaced airplane line number ranges with a reference to the Effectivity paragraph in the Planning Information section.
6. Summary, Compliance, added the effective date of the released Airworthiness Directive and added statement for an additional Airworthiness Directive.
7. Summary Illustration, added a new inspection area view, changed part names and the existing view title.
8. Paragraph 1.A, Effectivity, airplane line number applicability, variable number, group information and production revision record equivalent statements added.
9. Paragraph 1.C, Reason, added new inspection area, Service Related Problem reference, Fleet Team Digest reference and acronym definitions. Reason for revision information updated.
10. Paragraph 1.D, Description, updated layout of existing and new action descriptions using common airplane grouping. Removed corrective action descriptions and removed "write to Boeing for repair instructions" note. Removed alternate inspections statement for airplanes with service bulletin 737-53-1182 R1 repair or preventive modification. Replaced "More work" statement from Revision 1 with an "Effects of this Revision" table.
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11. Paragraph 1.E, Compliance, replaced "The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin" statement with the effective date of the released Airworthiness Directive, added statement for an additional Airworthiness Directive, and updated inspection types paragraph for the new and renumbered compliance tables.
12. Paragraph 1.E, Compliance, added new paragraphs for the definition of compliance table conditions, action, options and required actions accomplishment instructions.
13. Paragraph 1.E, Compliance, updated compliance table 1 starting conditions and related compliance thresholds. Clarified compliance table 1 BS 616 and BS 638 frame inspection locations for Option 1 and Option 2. Clarified frame crack and stub condition and corrective action wording. Added a new condition and a before further flight corrective action to compliance table 1 for any crack found in a stub beam to BL 45.5 floor beam attachment tee/angle. Compliance table 1, footnote (a) changed to refer to compliance table 2 for post partial frame replacement and integral stub beam replacement inspection requirements.
14. Paragraph 1.E, Compliance, changed compliance table 2 layout and Option 2 replacement frame web inspection requirements.
15. Paragraph 1.E, Compliance, added new compliance tables 3, 4, 5 and 9. Existing compliance tables 3, 4 and 5 renumbered as compliance tables 6, 7 and 8, respectively.
16. Paragraph 1.E, Compliance, added corrective actions to compliance table 8.
17. Paragraph 1.F, Approval, changed the FAA Aircraft Certification Office information.
18. Paragraph 1.G, Manpower, added Tables 8 and 9. Corrected Table 5, 6 and 7 titles. Corrected Table 6 task description.
19. Paragraph 1.J, References, updated existing data and installation drawing used in the preparation of this service bulletin.
20. Paragraph 1.M., Software Accomplishment Summary, not affected statement added.
21. Paragraph 2.A, Material, Price and Availability, added note for new Appendix B Part Demand Intent survey and updated kit price information.
22. Paragraph 2.C, Parts Necessary for Each Airplane, corrected Figure number for forming an Operator Supplied stiffening angle.
23. Paragraph 3.A, Accomplishment Instructions, added general information notes.
24. Paragraph 3.B, Work Instructions, Part 1, corrected inspection instructions for partial frame replacements, stub beam and stub beam attachment replacement, frame crack condition wording, and added channel/filler location note. Channel/filler removal and installation steps added to Option 1 and Option 2 instruction sequence.
25. Paragraph 3.B, Work Instructions, Part 2, added close access instruction and repeat inspection termination note.
26. Paragraph 3.B, Work Instructions, Part 3, added close access instruction and changed part title.
27. Paragraph 3.B, Work Instructions, Part 4, changed frame description in partial frame replacement steps.
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28. Paragraph 3.B, Work Instructions, Part 5, removed work instruction text duplicated with the related Figure.
29. Paragraph 3.B, Work Instructions, Part 6, added tapered shim installation instruction.
30. Paragraph 3.B, Work Instructions, Part 7, clarified work instructions and added notes.
31. Paragraph 3.B, Work Instructions, Parts 8 and 9 and Figures 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20, changed Non-Destructive Testing Manual references from 'Figure 1 or Figure 16' to 'Procedure 16'.
32. Paragraph 3.B, Work Instructions, Parts 8 and 9, changed to add airplane group applicability, a close work instruction step and to correct part names. Clarified Part 9 work instruction for open hole inspections common to the BL 45.5 floor beam attachment tee/angle, and added SRM repair of the BL 45.5 longitudinal floor beam web at BS 639 added as an instruction step with follow-up inspections.
33. Paragraph 3.B, Work Instructions, added new Parts 10 and 11.
34. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15 and 16, changed figure titles.
35. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 24, 25 and 26 changed illustration view titles and part names.
36. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 6, 7, 8, 9, 10, 24, 25, 26 and 27, QTY numbers and QTY statement removed.
37. Paragraph 3.B, Work Instructions, Figures 1, 2, 3, 11, 12, 13, 14, 15, 16, 25 and 26, corrected footnotes.
38. Paragraph 3.B, Work Instructions, Figures 2, 3, 7, 8, 9, 10, 12, 13, 15, 16, 17, 19 and 20, changed airplane locators.
39. Paragraph 3.B, Work Instructions, Figures 6, 7, 8, changed frame web, inner chord and outer chord inspection requirements.
40. Paragraph 3.B, Work Instructions, Figures 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 18, 19, 20, 24, 26 and 27, changed Non-Destructive Testing Manual references from 'Figure 4 or Figure 23' to 'Procedure 4 or Procedure 23'.
41. Paragraph 3.B, Work Instructions, Figures 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20, tapered shim installation footnote changed.
42. Paragraph 3.B, Work Instructions, Figures 11, 12, 13, 14, 15 and 16, corrected SRM references for stringer splicing information.
43. Paragraph 3.B, Work Instructions, Figure 27 changed to add inspection options and the data given in Alternative Method of Compliance (AMOC) Notice 737-53A1254-AMOC-03.
44. Paragraph 3.B, Work Instructions, added new Figures 28 and 29.
45. Appendix A, Inspection Report Form inspection heading corrected.
46. Added new Appendix B Part Demand Intent.
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The data given in Alternative Method of Compliance Notice 737-53A1254 AMOC 03 is included in this revision.
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 February 17, 2005Original Issue:
July 09, 2009Revision 1:
February 22, 2012Revision 2:
November 13, 2017Revision 3:
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Original Issue: February 17, 2005 737-53A1254Revision 3: November 13, 2017 10 of 192 BOEING SERVICE BULLETIN 737-53A1254
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BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1254Original Issue: February 17, 2005 Revision 3: November 13, 2017 ATA System: 5310 5710 SUBJECT: FUSELAGE - Frame and Overwing Stub Beam at Body Stations 616, 639 and 597 or 601 - Buttock Line 45.5 Floor Beam Web at Body Station 639 - Inspection and Repair
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND The cause of the cracks at Body Station (BS) 616 and BS 639 frame sections below Stringer (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 below S-15 to the lower end of the stub beam, frame inner chord lower end fastener holes, frame shear ties, stub beam structure at BS 616, 639 and 597 or 601 and BL 45.5 longitudinal floor beam at BS 639 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, 737-SRP-53-0516 and 737-SRP-53-0529 are related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 53-03003 is related to this service bulletin.
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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.
Remove seats, carpets, side panels and floor panels to get access to the overwing stub beams, both sides of the BL 45.5 longitudinal floor beam, and body frames at BS 616, 639, 597 or 601.
Do a detailed or High Frequency Eddy Current (HFEC) inspection of the BS 616 and BS 639 frame web, inner chord and outer chord from three fastener rows above S-16 down to the last fastener common to the stub beam joint, and the stub beam assembly from BL 45.5 to the outboard end, for any crack.
Group 1-2:
Do an open hole HFEC inspection for any crack in the BL 45.5 longitudinal floor beam web at each fastener hole common to the stub beam attachment angle, and do a HFEC surface inspection for any crack in the BL
45.5 longitudinal floor beam web, around the fastener head/tail at each fastener location common to the back-up strap. Do a detailed inspection of the frame shear ties at BS 597 for any crack.
Group 3:
Do a detailed or HFEC inspection of the frame inner chord common to the lowest four fastener holes at BS 601 for any crack.
Group 2-3:
Do a detailed and Medium Frequency Eddy Current (MFEC) subsurface inspection of the BS 616 stub beam upper chord for any crack.
Do the detailed, HFEC, and MFEC inspections at the thresholds given in the compliance section of this service bulletin. If no crack is found, repeat the detailed, HFEC, and MFEC 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/-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives (AD) AD 98-11-04 R1, AD 2008-09-13 and AD 2010-25-06 are related to this service bulletin. The effective date of AD 2010-25-06 is February 1, 2011.
The 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.
Refer to Paragraph 1.E., Compliance.
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.
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