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December 09, 2004 Revision 3: October 16, 2008 737-53A1262 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 650
ALERT ALERT Commercial Airplane Group 737
ALERTALERT Service Bulletin Number: 737-53A1262 Date: December 09, 2004 Revision 3: October 16, 2008 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin for Scribe Lines
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.
BLANK PAGE December 09, 2004 Revision 3: October 16, 2008 737-53A1262 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 650 BOEING SERVICE BULLETIN 737-53A1262
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Table of Contents December 09, 2004 Revision 3: October 16, 2008 737-53A1262 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 650 BOEING SERVICE BULLETIN 737-53A1262
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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 79
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 79 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 79
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 81
3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 81
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 FIGURE 1: COMPLIANCE THRESHOLD CALCULATION FOR ZONE 1 . . . . . . . . . . . . . . . . 123 FIGURE 2: COMPLIANCE THRESHOLD CALCULATION FOR ZONE 2 . . . . . . . . . . . . . . . . 130 FIGURE 3: COMPLIANCE THRESHOLD CALCULATION FOR ZONE 3 . . . . . . . . . . . . . . . . 136 FIGURE 4: ZONE 1 - GROUP 1 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 FIGURE 5: ZONE 1 - GROUP 2 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 FIGURE 6: ZONE 1 - GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 FIGURE 7: ZONE 1 - GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 FIGURE 8: ZONE 1 - GROUP 7 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 FIGURE 9: ZONE 1 - GROUP 10 AND 31 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . 171 FIGURE 10: ZONE 1 - GROUP 13 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 FIGURE 11: ZONE 1 - GROUP 14 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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FIGURE 12: ZONE 1 - GROUP 15 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 FIGURE 13: ZONE 2 - GROUP 1 AND 2 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . 198 FIGURE 14: ZONE 2 - GROUP 3 AND 29 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 202 FIGURE 15: ZONE 2 - GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 FIGURE 16: ZONE 2 - GROUP 7 AND 8 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 210 FIGURE 17: ZONE 2 - GROUP 9, 10, 11, AND 31 AIRPLANES. . . . . . . . . . . . . . . . . . . . 214 FIGURE 18: ZONE 2 - GROUP 13 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 FIGURE 19: ZONE 2 - GROUP 14 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 FIGURE 20: ZONE 2 - GROUP 15 AND 21 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . 227 FIGURE 21: ZONE 3 - GROUP 1, 2, AND 28 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . 232 FIGURE 22: ZONE 3 - GROUP 3 AND 29 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 236 FIGURE 23: ZONE 3 - GROUP 4 AND 30 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 240 FIGURE 24: ZONE 3 - GROUP 6 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 FIGURE 25: ZONE 3 - GROUP 7 AND 8 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . 250 FIGURE 26: DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 FIGURE 27: ZONE 3 - GROUP 9, 10, 11, AND 31 AIRPLANES. . . . . . . . . . . . . . . . . . . . 255 FIGURE 28: DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 FIGURE 29: ZONE 3 - GROUP 12 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 FIGURE 30: ZONE 3 - GROUP 13 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 FIGURE 31: ZONE 3 - GROUP 14 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 FIGURE 32: ZONE 3 - GROUP 15 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 FIGURE 33: ZONE 3 - GROUP 16 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 FIGURE 34: LAP JOINT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 FIGURE 35: SKIN BUTT JOINT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3 FIGURE 36: SKIN INSPECTION AT EXTERNAL DOUBLERS . . . . . . . . . . . . . . . . . . . . 285 FIGURE 37: IDENTIFICATION OF THE "RESTRICTED ZONES" 1B AT DOOR CUTOUTS . . . . . 287 FIGURE 38: SKIN INSPECTION AROUND THE WING-TO-BODY FAIRING . . . . . . . . . . . . . 289 FIGURE 39: SKIN INSPECTION AT DOUBLERS OR SCUFF PLATES IN THE "RESTRICTED ZONES" 1B AT DOOR CUTOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 FIGURE 40: ZONE 1A LIMITED RETURN TO SERVICE (LRTS) LOGIC DIAGRAM . . . . . . . . . 296 FIGURE 41: ZONE 1B LIMITED RETURN TO SERVICE (LRTS) LOGIC DIAGRAM . . . . . . . . . 300 FIGURE 42: ZONE 2 LIMITED RETURN TO SERVICE (LRTS) LOGIC DIAGRAM . . . . . . . . . . 303 FIGURE 43: ZONE 3 LIMITED RETURN TO SERVICE (LRTS) LOGIC DIAGRAM . . . . . . . . . . 306 FIGURE 44: INTERNAL LAP JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 309 FIGURE 45: ZONE 1 - GROUP 6 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 FIGURE 46: ZONE 1 - GROUP 8 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 FIGURE 47: ZONE 1 - GROUP 9 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 FIGURE 48: ZONE 1 - GROUP 11 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 FIGURE 49: ZONE 1 - GROUP 12 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 FIGURE 50: ZONE 2 - GROUP 12 AND 17 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . 344 FIGURE 51: ZONE 2 - GROUP 16 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 FIGURE 52: ZONE 1 - GROUP 17 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 FIGURE 53: ZONE 3 - GROUP 17 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 FIGURE 54: ZONE 1 - GROUP 18 AND 27 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . 363 FIGURE 55: ZONE 2 - GROUP 18 AND 27 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . 370 FIGURE 56: ZONE 3 - GROUP 18 AND 27 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . 375
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FIGURE 57: ZONE 1 - GROUP 19 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 FIGURE 58: ZONE 2 - GROUP 19 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 FIGURE 59: ZONE 3 - GROUP 19 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 FIGURE 60: ZONE 1 - GROUP 20 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 FIGURE 61: ZONE 2 - GROUP 20 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399 FIGURE 62: ZONE 3 - GROUP 20 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 FIGURE 63: ZONE 1 - GROUP 21 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406 FIGURE 64: ZONE 3 - GROUP 21 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 FIGURE 65: ZONE 1 - GROUP 22 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418 FIGURE 66: ZONE 2 - GROUP 22 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 FIGURE 67: ZONE 3 - GROUP 22 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430 FIGURE 68: ZONE 1 - GROUP 23 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434 FIGURE 69: ZONE 2 - GROUP 23 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 FIGURE 70: ZONE 3 - GROUP 23 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446 FIGURE 71: ZONE 1 - GROUP 24 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 FIGURE 72: ZONE 2 - GROUP 24 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 FIGURE 73: ZONE 3 - GROUP 24 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 FIGURE 74: ZONE 1 - GROUP 25 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466 FIGURE 75: ZONE 2 - GROUP 25 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473 FIGURE 76: ZONE 3 - GROUP 25 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 FIGURE 77: ZONE 1 - GROUP 26 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482 FIGURE 78: ZONE 2 - GROUP 26 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 FIGURE 79: ZONE 3 - GROUP 26 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492 FIGURE 80: ZONE 4 LIMITED RETURN TO SERVICE (LRTS) LOGIC DIAGRAM . . . . . . . . . . 496 FIGURE 81: ZONE 5 LIMITED RETURN TO SERVICE (LRTS) LOGIC DIAGRAM . . . . . . . . . . 497 FIGURE 82: ZONE 4 - GROUP 2 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 FIGURE 83: ZONE 4 - GROUP 28 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 FIGURE 84: ZONE 4 - GROUP 3 AND 29 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . 502 FIGURE 85: ZONE 4 - GROUP 4 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504 FIGURE 86: ZONE 4 - GROUP 5 AND 30 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . . . 505 FIGURE 87: ZONE 4 - GROUP 6 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507 FIGURE 88: ZONE 4 - GROUP 7, 9, AND 10 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . 509 FIGURE 89: ZONE 4 - GROUP 8, 11, AND 31 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . 511 FIGURE 90: ZONE 4 - GROUP 12 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 FIGURE 91: ZONE 4 - GROUP 13 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515 FIGURE 92: ZONE 4 - GROUP 16 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517 FIGURE 93: ZONE 4 - GROUP 14 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 FIGURE 94: ZONE 4 - GROUP 18 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 FIGURE 95: ZONE 4 - GROUP 19 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523 FIGURE 96: ZONE 4 - GROUP 20 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525 FIGURE 97: ZONE 4 - GROUP 27 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527 FIGURE 98: ZONE 4 - GROUP 15 AND 21 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 529 FIGURE 99: ZONE 4 - GROUP 22 AND 23 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 532 FIGURE 100: ZONE 4 - GROUP 24 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535 FIGURE 101: ZONE 4 - GROUP 25 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538 FIGURE 102: ZONE 4 - GROUP 26 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540
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FIGURE 103: ZONE 5 - GROUP 2 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543 FIGURE 104: ZONE 5 - GROUP 28 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 545 FIGURE 105: ZONE 5 - GROUP 3 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547 FIGURE 106: ZONE 5 - GROUP 29 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 549 FIGURE 107: ZONE 5 - GROUP 4, 5, 6, AND 30 AIRPLANES . . . . . . . . . . . . . . . . . . . . 551 FIGURE 108: ZONE 5 - GROUP 7, 8, 9, 10, 11, 12, 17, AND 31 AIRPLANES . . . . . . . . . . . . 552 FIGURE 109: ZONE 5 - GROUP 13 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 554 FIGURE 110: ZONE 5 - GROUP 16 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 556 FIGURE 111: ZONE 5 - GROUP 14 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 558 FIGURE 112: ZONE 5 - GROUP 18 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 559 FIGURE 113: ZONE 5 - GROUP 19 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 FIGURE 114: ZONE 5 - GROUP 20 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 563 FIGURE 115: ZONE 5 - GROUP 27 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 565 FIGURE 116: ZONE 5 - GROUP 15 AND 21 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . 567 FIGURE 117: ZONE 5 - GROUP 22 AND 23 AIRPLANES. . . . . . . . . . . . . . . . . . . . . . . 569 FIGURE 118: ZONE 5 - GROUP 24 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 572 FIGURE 119: ZONE 5 - GROUP 25 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 575 FIGURE 120: ZONE 5 - GROUP 26 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 578 FIGURE 121: ZONE 1 - GROUP 28 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 581 FIGURE 122: ZONE 1 - GROUP 29 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 587 FIGURE 123: ZONE 1 - GROUP 30 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 593 FIGURE 124: ZONE 1 - GROUP 16 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 FIGURE 125: ZONE 2 - GROUP 28 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 605 FIGURE 126: ZONE 2 - GROUP 5 AND 6 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . 609 FIGURE 127: ZONE 3 - GROUP 5 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613 FIGURE 128: REQUIRED INSPECTIONS FOR SCRIBES FOUND WITHIN ONE INCH OF A LAP JOINT, REPAIR DOUBLER, OR SCUFF PLATE . . . . . . . . . . . . . . . . . . . . . . . . 618 FIGURE 129: ZONE 4 - GROUP 17 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 620 FIGURE 130: ZONE 2 - GROUP 30 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . 622 FIGURE 131: ZONE 1 - GROUP 5 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626 APPENDIX A: SEALANT REMOVAL PROCEDURE FOR EXTERIOR PRESSURIZED FUSELAGE SKIN 632 APPENDIX B: REPORTING SYSTEM - LIMITED RETURN TO SERVICE PROCEDURE FOR SCRIBED AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638 APPENDIX C: AIRPLANE FUSELAGE SCRIBE MARK SUMMARY TABLES. . . . . . . . . . . . . 641 APPENDIX D: DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644 APPENDIX E: DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645 APPENDIX F: DELETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646 APPENDIX G: DELETED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 647 APPENDIX H: SCRIBE SAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648 APPENDIX I: APPLICATION OF PAINT-REPLACING FILM . . . . . . . . . . . . . . . . . . . . . 650
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ALERT ALERT Commercial Airplane Group 737
ALERTALERT Service Bulletin Number: 737-53A1262 Revision Transmittal Sheet Date: December 09, 2004 Revision 3: October 16, 2008 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin for Scribe Lines This Revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes inspected as shown in Revision 2 of this Service Bulletin. If scribes were found as a result of the inspections shown in the original issue or Revision 1 or Revision 2 of this service bulletin, but not repaired, continue to do inspections as shown in this revision.
REASON FOR REVISION This revision is sent to add notes and examples to clarify compliance conditions for limited return to service (LRTS) repeat inspection.
The changes to this service bulletin include:
— Paragraph 1.E. Compliance. Step 5. Changes are made to clarify the compliance for follow on inspections.
— Paragraph 1.K. Publications Affected. Changed the referenced Structural Repair Manual to Aircraft Maintenance Manual.
— Paragraph 3.B. Work Instructions. Part 12. Moved note from step 8.a. to Step 8.
— Paragraph 3.B. Work Instructions. Part 16 - Zone 5 Inspections. Correct the Zone 4 call out to Zone 5.
— Figure 5. Correct the location of stringer 25.
— Figure 17 and Figure 50. Locations of stringer 16 left and stringer 16 right are added.
— Figure 40, 41, 42 and 43. New notes and examples of compliance times are added for clarification.
— Figure 62. Inspection around the left and right side aft wing to body fairings has been removed.
— Appendix B. Additional Service Bulletin Inspections. Service bulletin references are updated.
The data given in Information Notice 737-53A1262 IN 02 is included in this revision. IN 02 was sent to tell operators that the table in Paragraph 1.K., Publications Affected, should refer to 737 Aircraft Maintenance Manual (AMM) Chapter-Section 51-31, not 737 Structural Repair Manual Chapter-Section 51-31.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.
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.
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REVISION HISTORY Original Issue: December 9, 2004 Revision 1: March 1, 2007 Revision 2: September 20, 2007 Revision 3: October 16, 2008
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ALERT ALERT Commercial Airplane Group 737
ALERTALERT Service Bulletin Number: 737-53A1262 Summary Date: December 09, 2004 Revision 3: October 16, 2008 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Inspections of the Fuselage Skin for Scribe Lines
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 gives instructions for the inspection and repair of scribe lines in the fuselage skin at lap joints, certain butt joints, around the wing-to-body fairing, decals, and at certain external doublers and scuff plates. Fatigue cracks can develop in the skin at scribe line locations. Fatigue cracks in the skin that remain undetected could grow large and cause sudden decompression.
Two operators have told Boeing about fuselage skin cracks that were found adjacent to the skin lap joints on two 737-200 airplanes with scribe lines. On the first airplane, a 5 inch long crack was found at STA 827, just below the lap joint at S-4R. This airplane had flown a total of 52,226 flight-cycles. On the second airplane, two cracks were found below the S-10R lap joint. A ten inch long crack was found between STA 757 and STA 767, and a five inch long crack was found between STA 749 and STA 754. This airplane had flown a total of 41,899 flight-cycles. Both airplanes were also found to have scribe lines along the lap joints, butt joints, and around the wing-to-body fairing. The scribe lines appear to have been made on the skin when sealant was removed as part of preparation of the airplane for repainting.
The cracked skin areas were sent to Boeing for analysis. The analysis confirmed that the cracks initiated at the scribe lines, which were found to be 0.002 - 0.004 inch deep. Metallurgical analysis by Boeing indicated that the cracks initiated at multiple sites along the scribe line. The total flight-cycles from crack initiation to a fullthickness crack was 5,500 on the first airplane and 6,000 on the second airplane.
As a result of these reports, an additional 156 airplanes have been specifically inspected for scribe lines. Of these, 116 airplanes were found to have multiple scribe lines along the lap joints, butt joints, and around the wing-to-body fairing.
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Accomplishment of the inspections shown in this service bulletin will help make sure that fatigue cracks that can form in the skin at scribe lines are found and repaired before they can become large and cause sudden loss of cabin pressure.
A scribe line is defined as a narrow, shallow, distinct line of damage (up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (lap joints and butt splices, respectively). A more detailed definition of a scribe line is included in Paragraph 3.A., Accomplishment Instructions.
Boeing Service Related Problem (SRP) 737-SRP-53-0214 is related to this service bulletin.
ACTION (PRR35005-262RS) This service bulletin gives instructions for the inspection and repair of scribe lines in the fuselage skin at lap joints, butt joints, around the wing-to-body fairing, and at certain external doublers or door scuff plates. A scribe line is a narrow, shallow, distinct line of damage (up to 0.006 inch deep), usually associated with the removal of a fillet or gap seal (lap joints and butt splices, respectively). A more detailed definition of a scribe line is included in Paragraph 3.A., Accomplishment Instructions.
A review of fleet activity yields three separate scenarios that are suspected to have caused scribe line damage to the fuselage skin or butt joint splice straps.
Refer to Paragraph 1.D., Description for details.
EFFECTIVITY All 737-100, 737-200, 737-200C, 737-300, 737-400, and 737-500 airplanes in 31 groups.
COMPLIANCE Refer to Paragraph 1.E., Compliance.
Federal Aviation Administration (FAA) Airworthiness Directive 2006-07-12 is related to this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspections or repair procedures given in this service bulletin.
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MANPOWER NOTE: More time will be required for repairs or additional inspections if scribe lines or cracks are found.
MATERIAL INFORMATION None.
Task Total Task Hours Elapsed Hours Inspect Zone 1 70 17.5 Inspect Zone 2 41 10.25 Inspect Zone 3 92 23 Inspect Zone 4 16 4 Inspect Zone 5 32.5 8.5 Total 251.5 63.25
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