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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1255 Original Issue: October 17, 2002 Revision 2: August 07, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Crown Skin Lap Joint - Inspection for Lower Row Cracking at Stringers S-4, S-10, S-14 Between STA 360 and STA 908 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 © 2002 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Unpublished Work.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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management Company.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 1 of 108
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 2 of 108 BOEING SERVICE BULLETIN 737-53A1255
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BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 5 B. Concurrent Requirements ...................................... 2 6 C. Reason ................................................ 2 6 D. Description .............................................. 2 7 E. Compliance .............................................. 2 8 F. Approval ............................................... 3 5 G. Manpower .............................................. 3 6 H. Weight and Balance Changes .................................... 4 4 I. Electrical Load Data ......................................... 4 4 J. References .............................................. 4 5
1. Existing Data: ......................................... 4 5
2. Data Supplied with this Service Bulletin: ........................... 4 5
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 5 K. Publications Affected ........................................ 4 6 L. Interchangeability and Intermixability of Parts ........................... 4 6 M. Software Accomplishment Summary ................................ 4 6
2. MATERIAL INFORMATION ........................................ 4 7 A. Material - Price and Availability ................................... 4 7 B. Industry Support Information .................................... 4 7 C. Parts Necessary for Each Airplane ................................. 4 7
1. Kits/Parts: ........................................... 4 7
2. Parts and Materials Supplied by the Operator: ........................ 4 7
3. Parts Modified and Reidentified: ............................... 4 7
4. Parts Removed and Not Replaced: .............................. 4 7 D. Parts Necessary to Change Spares ................................. 4 7 E. Special Tooling - Price and Availability ............................... 4 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 0 FIGURE 1: INTERNAL INSPECTION - CROWN LAP JOINTS AND STRINGER CLIPS ........ 6 9 FIGURE 2: EXTERNAL INSPECTION - CROWN LAP JOINTS ..................... 7 1 FIGURE 3: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 1] ........... 7 3 FIGURE 4: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 2] ........... 7 5 FIGURE 5: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 3] ........... 7 7 FIGURE 6: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 4] ........... 7 9 FIGURE 7: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 5] ........... 8 1 FIGURE 8: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 6] ........... 8 3 FIGURE 9: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 7] ........... 8 5 FIGURE 10: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 8] ........... 8 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 3 of 108 BOEING SERVICE BULLETIN 737-53A1255
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FIGURE 11: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 9] ........... 8 9 FIGURE 12: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 10] .......... 9 1 FIGURE 13: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 11] .......... 9 3 FIGURE 14: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 12] .......... 9 5 FIGURE 15: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 13] .......... 9 7 FIGURE 16: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 14] .......... 9 9 FIGURE 17: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 15] .......... 1 0 1 FIGURE 18: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 16] .......... 1 0 3 FIGURE 19: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 17] .......... 1 0 5 FIGURE 20: INSPECTION ZONES AT THE CROWN LAP JOINT AREA [Group 18] .......... 1 0 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 4 of 108 BOEING SERVICE BULLETIN 737-53A1255
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1255Original Issue: October 17, 2002 Revision 2: August 07, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Crown Skin Lap Joint - Inspection for Lower Row Cracking at Stringers S-4, S-10, S-14 Between STA 360 and STA 908 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes inspected in accordance with Revision 1 of this service bulletin.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-08-15 is related to this service bulletin.
REASON FOR REVISION This revision is sent to incorporate additional compliance notes in Paragraph 1.E., Compliance and additional inspection notes in Paragraph 3.B., Work Instructions.
These sections were changed:
1. Paragraph 1.E., Compliance, added new compliance notes.
2. Paragraph 1.F., Approval, changed service bulletin revision number.
3. Added Paragraph 1.M., Software Accomplishment Summary.
4. Paragraph 3.B., Work Instructions, added new inspection notes.
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 October 17, 2002Original Issue:
November 07, 2011Revision 1:
August 07, 2012Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 5 of 108
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 6 of 108 BOEING SERVICE BULLETIN 737-53A1255
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1255Original Issue: October 17, 2002 Revision 2: August 07, 2012 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Crown Skin Lap Joint - Inspection for Lower Row Cracking at Stringers S-4, S-10, S-14 Between STA 360 and STA 908
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 This service bulletin outlines additional inspection requirements with reduced compliance times from that described in service bulletin 737-53A1177 for stringer S-4L & S-4R skin lap joints between STA 360-STA 908, S-10L, S-10R, S-14L, S-14R between STA 360-STA 540 and STA 727-STA 908.
Two findings, one discovered on September 11, 2002 on a 737-300 with 52,400 flight cycles and the other discovered on December 31, 2001 on a 737-200 with 60,333 flight cycles have caused increased concern with the extent of lap joint lower row cracking.
On December 31, 2001 during a walk-around inspection on a 737-200 with 60,333 flight cycles, a 23 inch long crack was found in the lower row of the stringer S-4L lap joint between STA 616 and STA 639. The technician noticed the crack above the over-wing exit, because the lower skin was pushed outward approximately 1 inch with the crack ends turning downward at the tear straps. There was no report from the flight crew of pressurization problems or from passenger or cabin crew of any abnormal noise in the area. The operator elected to inspect the lap joint for additional cracks using external and internal NDT methods. Additional cracks were found.
Following a local repair of the 23 inch long crack the operator ferried the airplane unpressurized to a maintenance facility to perform the 737-53A1177 lap joint modification. The removed lap joints were inspected by Boeing NDT personnel using the current methods referenced in service bulletin 737-53A1177 and significantly more cracks were found.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 7 of 108
Boeing is concerned about the extent of cracking both forward and aft of the 23 inch long cracked section. Cracks were found in between the tear straps and in the skin at locations common to the tear straps. The in-tact tear straps were able to turn the cracks as they were designed to do. However, due to the condition of the skin at the tear straps forward and aft of the 23 inch crack area, it is likely that similar crack link-up just forward in an area which had a higher percentage of cracked fastener holes could have resulted in an uncontained decompression. Of great importance is the total number and length of cracks found at this particular lap joint.
The damage observed is believed to exceed all prior in-service crack findings and Boeing predictions based on test and analysis for an airplane with 60,000 flight cycles.
On September 11, 2002 Boeing NDT personnel, while assisting an operator of a 737-300 with 52,400 flight cycles, discovered significant cracking on the stringer S-4R lap joint between STA 600 and STA 727. At one location between STA 639 and STA 650, every fastener hole (11 total) had a crack of over 0.5 inches emanating from each side. Although the individual cracks had not yet linked up, it was clear that within a few number of flights the cracks would have linked up with a length of over 10 inches. Forward of this section between STA 636 and STA 620, 15 fastener holes in a row were cracked. This included the skin common to the tear strap at STA 630. Although these cracks were only 0.2 inches long, there were only 4 crack free fastener holes separating the two cracked areas. Additionally, 3 stringer clips common to S-4 were found to be cracked. The clip at STA 639 was completely severed and the clips at STA 616 and STA 663.75 were partially cracked. Stringer clips were redesigned beginning at line position 1001. Service bulletin 737-53-1268, which superseded service bulletin 737-53-1085 provides retrofit instructions for airplanes built prior to line position 1001. Service bulletin 737-53-1268 also inspects for damaged stringer clips for airplanes line positions 1001 to 3132. The cracks in the lap joints were found using the LFEC external inspection method and verified using the MFEC inspection method which are called out in service bulletin 737-53A1177. Previous inspection by the operator found significantly less cracking. Boeing NDT personnel were able to locate over eight times as many cracks.
If the cracks continue to grow undetected they will link-up. Independent large scale fatigue testing at Boeing has shown that this extent of cracking can result in an uncontrolled decompression.
Since the release of service bulletin 737-53A1177 Revision 6 and the original issue of this service bulletin there have been many reports of crack findings. On 33 airplanes between 36,781 flight cycles and 68,884 flight cycles lap joint damage has been found, with cracking lengths ranging from 0.03 inches to 0.10 inches, with the exception of the more significant cracking noted above. Cracks have also been found in lap joint lower skins that do not intersect fastener holes. Boeing has completed a re-evaluation of the compliance requirements for the lap joints.
As a result of the re-evaluation the inspection recommendations of the crown lap joints between STA 360 - STA 908 are updated. This update includes a reduced inspection threshold and repeat inspections. Accomplishment of service bulletin 737-53A1177 lap joint modification is mandated by AD 2002-07-08 to be accomplished before 50,000 total flight cycles.
Boeing Service Related Problem (SRP) 737-SRP-53-0372 is related to this service bulletin.
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 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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ReferenceAffectedPlanning Data 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 YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Do a Non-Destructive Test (NDT) eddy current inspection of the external fuselage crown lap joints (S-4L/R, S-10L/R, and S-14L/R) between STA 360 and STA 908 at specific locations.
Get access to the interior fuselage and do Non-Destructive Test (NDT) eddy current and detailed inspections of the internal fuselage crown lap joints (S-4L/R, S-10L/R, and S-14L/R) and detailed inspections of the stringer clips between STA 360 and STA 908 at specific locations.
If no cracks are detected continue inspections in accordance with Paragraph 1.E., Compliance.
If any crack is found in a crown lap joint repair in accordance with 737-100/200 SRM 53-30-3, Figure 42, 737-300 SRM 53-00-01, Figure 201, Repair 30, 737-400 SRM 53-00-01, Figure 201, Repair 30 or 737-500 SRM 53-00-01, Figure 201, Repair 30.
Replace any damaged stringer clips with new clips.
EFFECTIVITY 737-200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2003-08-15 is related to this service bulletin.
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.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 9 of 108 BOEING SERVICE BULLETIN 737-53A1255
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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: October 17, 2002 737-53A1255Revision 2: August 07, 2012 10 of 108 BOEING SERVICE BULLETIN 737-53A1255
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BOEING SERVICE BULLETIN 737-53A1255
ALERT ALERT FRAME STA
STRINGER CLIP
INSPECT LAP JOINT AND
STRINGER CLIPS BETWEEN
STRINGER STA 360 AND STA 908
TYPICAL CRACK FWD < S-4L
TEAR STRAP TYPICAL WHERE THE LOWER
SKIN IS NOT COVERED
TYPICAL WHERE THE TEAR STRAP OR
DOUBLER COVERS THE LOWER SKIN 2 FWD TYPICAL LAP JOINT CONFIGURATION N59209 Original Issue: October 17, 2002 Revision 2: August 07, 2012 Export Controlled ECCN: 9E991 - BOEING 737-53A1255 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 108
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: October 17, 2002 737-53A1255Revision 2: August 07, 2012 12 of 108 BOEING SERVICE BULLETIN 737-53A1255