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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1279 Original Issue: December 18, 2007 Revision 1: September 02, 2011 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Cargo Bay Stringer 19 to Stringer 21
- Frames and Frame Reinforcements - Inspection, Repair and Preventative Modification at Wire Penetration Hole 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 1 of 159
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 2 of 159 BOEING SERVICE BULLETIN 737-53A1279
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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 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 8 D. Description .............................................. 1 9 E. Compliance .............................................. 2 0 F. Approval ............................................... 2 4 G. Manpower .............................................. 2 5 H. Weight and Balance Changes .................................... 2 6 I. Electrical Load Data ......................................... 2 7 J. References .............................................. 2 7
1. Existing Data: ......................................... 2 7
2. Data supplied with this Service Bulletin: ........................... 2 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 7 K. Publications Affected ........................................ 2 8 L. Interchangeability and Intermixability of Parts ........................... 2 8
2. MATERIAL INFORMATION ........................................ 2 9 A. Material - Price and Availability ................................... 2 9 B. Industry Support Information .................................... 2 9 C. Parts Necessary For Each Airplane ................................. 2 9
1. Kits/Parts: ........................................... 2 9
2. Parts and Materials Supplied by the Operator: ........................ 2 9
3. Parts Modified and Reidentified: ............................... 2 9
4. Parts Removed and Not Replaced: .............................. 2 9 D. Parts Necessary to Change Spares ................................. 2 9 E. Special Tooling - Price and Availability ............................... 2 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1 A. GENERAL INFORMATION ..................................... 3 1 B. WORK INSTRUCTIONS ....................................... 3 1 FIGURE 1: FORWARD CARGO BAY - STATION 500A TO STATION 500D - WIRE SHROUD - REMOVAL [Group 1] ............................................ 4 1 FIGURE 2: FORWARD CARGO BAY - STATION 460 TO STATION 482B - WIRE SHROUD - REMOVAL [Group 3] ............................................ 4 5 FIGURE 3: FORWARD CARGO BAY - AFT BULKHEAD PANELS - REMOVAL ............ 4 9 FIGURE 4: FORWARD CARGO BAY - POWER FEEDER CABLE GUIDE ASSEMBLY - MOVE [Group 1] .................................................. 5 1 FIGURE 5: FORWARD CARGO BAY - POWER FEEDER CABLE GUIDE ASSEMBLY - MOVE [Group 2] .................................................. 5 6 FIGURE 6: FORWARD CARGO BAY - POWER FEEDER CABLE GUIDE ASSEMBLY - MOVE [Group 3] .................................................. 6 1
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FIGURE 7: FORWARD CARGO BAY - STATION 500B TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) SURFACE INSPECTION [Group 1] ................... 6 6 FIGURE 8: FORWARD CARGO BAY - STATION 500B TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) SURFACE INSPECTION [Group 2] ................... 7 3 FIGURE 9: FORWARD CARGO BAY - STATION 482 TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) SURFACE INSPECTION [Group 3] ................... 8 0 FIGURE 10: FORWARD CARGO BAY - STATION 500B TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) HOLE/EDGE INSPECTION [Group 1] .................. 8 7 FIGURE 11: FORWARD CARGO BAY - STATION 500B TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) HOLE/EDGE INSPECTION [Group 2] .................. 9 5 FIGURE 12: FORWARD CARGO BAY - STATION 482 TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) HOLE/EDGE INSPECTION [Group 3] ................. 1 0 3 FIGURE 13: FORWARD CARGO BAY - STATION 500B TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) HOLE/EDGE INSPECTION [Group 1] ................. 1 1 1 FIGURE 14: FORWARD CARGO BAY - STATION 500B TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) HOLE/EDGE INSPECTION [Group 2] ................. 1 1 9 FIGURE 15: FORWARD CARGO BAY - STATION 482 TO 520 FRAMES - HIGH FREQUENCY EDDY CURRENT (HFEC) HOLE/EDGE INSPECTION [Group 3] ................. 1 2 7 FIGURE 16: FORWARD CARGO BAY - POWER FEEDER CABLE GUIDE ASSEMBLY - INSTALL [Group 1 ] ................................................ 1 3 5 FIGURE 17: FORWARD CARGO BAY - POWER FEEDER CABLE GUIDE ASSEMBLY - INSTALL [Group 2 ] ................................................ 1 4 0 FIGURE 18: FORWARD CARGO BAY - POWER FEEDER CABLE GUIDE ASSEMBLY - INSTALL [Group 3 ] ................................................ 1 4 5 FIGURE 19: FORWARD CARGO BAY - AFT BULKHEAD PANELS - INSTALL ............ 1 5 0 FIGURE 20: FORWARD CARGO BAY - STATION 500A TO STATION 500D - WIRE SHROUD - INSTALL [Group 1] ............................................ 1 5 2 FIGURE 21: FORWARD CARGO BAY - STATION 460 TO STATION 482B - WIRE SHROUD - INSTALL [Group 3] ............................................ 1 5 6
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Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 4 of 159 BOEING SERVICE BULLETIN 737-53A1279
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1279Original Issue: December 18, 2007 Revision 1: September 02, 2011 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Cargo Bay Stringer 19 to Stringer 21
- Frames and Frame Reinforcements - Inspection, Repair and Preventative Modification at Wire Penetration Hole This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-02-06 R1 is related to this service bulletin.
No More work is necessary on the airplanes changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION This revision is sent to update Paragraph 1.E.Compliance with new inspection thresholds and separate compliance tables by airplane group. More background information is added and other references are updated throughout.
These sections were changed:
1. Paragraph 1.C.Reason - added background information
2. Paragraph 1.D.Description - added request for information from operators
3. Paragraph 1.E.Compliance - updated and added new table, added DTI information
4. Paragraph 1.F.Approval - added AD information
5. Paragraph 1.J.References - added AD and SRP information
6. Paragraph 1.K.Publications Affected - added DTI statement
7. Minor text updates throughout 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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Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 5 of 159
REVISION HISTORY December 18, 2007Original Issue:
September 02, 2011Revision 1:
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Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 6 of 159 BOEING SERVICE BULLETIN 737-53A1279
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1279Original Issue: December 18, 2007 Revision 1: September 02, 2011 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Cargo Bay Stringer 19 to Stringer 21
- Frames and Frame Reinforcements - Inspection, Repair and Preventative Modification at Wire Penetration Hole
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 to inspect a wire penetration hole for cracking in the forward cargo compartment frames and frame reinforcements, between Stringer S-20 and S-21, on both left and right sides of the airplane. It also provides repair instructions for cracking at the wire penetration hole and instructions for a preventative modification. Undetected cracking in fuselage frames at the wire penetration hole intended for wire routing will reduce the frames structural capability below fail-safe load limits. Undetected cracking in the frames could lead to cracking in the skin and could result in rapid depressurization of the airplane.
Boeing has received reports of cracking in the frame, or in the frame and frame reinforcement, common to the
1.04 inch nominal diameter wire penetration hole intended for wire routing, between S-20 and S-21, on both left and right sides of the airplane. The cracked frames are located between Station (STA) 500B and STA 520 on 737-300/400 airplanes and STA 482 and STA 520 on 737-500 airplanes.
Cracking is occurring at the 1.04 inch nominal diameter wire penetration hole due to the effect of operating loads in combination with the stress concentration at the 1.04 inch nominal hole.
Boeing received a report of frame cracking from an operator at the 1.04 inch nominal diameter wire penetration hole on a 737-400 airplane. The airplane had one cracked frame. Boeing has since received reports of more than fifty cracked frames at the 1.04 inch nominal diameter wire penetration hole on more than twenty airplanes, all either 737-300 or 737-500 airplanes. The airplanes had accumulated between 35,832 and 66,694 flight cycles.
The cracking initiated at the 1.04 inch nominal diameter wire penetration hole and grew towards the inner chord.
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Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 7 of 159
Boeing received a report of four cracked frames at BS 500B, BS 500C, BS 500D and BS 520 in the forward cargo compartment between S-20L and S-21L on a 737-300 airplane. The cracks at BS 500B and BS 500C were completely through the frame and fail-safe chord. The BS 500B frame was also cracked on the right hand side. The airplane had 44,535 flight cycles and 44,876 flight hours. Though the airplane was above the AD and service bulletin threshold of 32,000 flight cycles, the cracking was discovered before the airplane had reached the compliance time of the AD and of the original issue of this service bulletin.
In total, Boeing has received more than 50 reports of frame cracking at the 1.04 inch nominal diameter wire penetration hole on 24 airplanes. Details of the cracking are as follows:
— The cracking occurred at three frame stations on 737-300 airplanes, on four frame stations on 737-500 airplanes, and at one frame station on one 737-400 airplane.
— Sixteen airplanes had cracking on multiple frames.
— 10 frames had cracking at adjacent frames.
— 43 frames had cracking only at the inboard side of the 1.04 inch nominal diameter wire penetration hole in the frame inner chord or in the frame and frame reinforcement inner chord.
— 3 frames had cracking at the outboard side of the 1.04 inch nominal diameter wire penetration hole in the frame and the frame reinforcement. 2 of these frames were severed.
— Some frames had additional cracking at either the standoff/tooling holes or at the 0.50 inch diameter hole positioned below the 1.04 inch nominal diameter wire penetration hole.
This service bulletin gives instructions to inspect the 1.04 inch nominal diameter wire penetration hole for cracking in the frame and frame reinforcement, between S-20 and S-21, on both left and right sides of the airplane. It also provides repair instructions for cracking at the wire penetration hole and instructions for a preventative modification. An Inspection for cracking of the area and any necessary repair will assure the structural integrity of the fuselage.
Boeing Service Related Problem (SRP) 737-SRP-53-0289 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-53-0377 is related to this service bulletin.
ACTION Get access to the forward cargo bay. Remove the cargo handling system, if installed. Remove the wire shrouds, sidewall linings, aft bulkhead panels and insulation blankets, on both sides of the airplane to get access to frames STA 500B - STA 520 on 737-300 and -400 airplanes and STA 482 - STA 520 on 737-500 airplanes. Unscrew the power feeder cable guides as required, and move them away from the hole. Do a High Frequency Eddy Current (HFEC) inspection of the frame and frame reinforcement between S-20 and S-21 for cracking. If cracking is found at the 1.04 inch nominal diameter wire penetration hole, do additional HFEC inspections for cracking at the 0.50 inch diameter hole between S-20 and S-21 and all standoff/tooling hole locations between S-19 and S-22. If no additional cracking is found at the 0.50 inch or standoff/tooling holes, repair cracking at the wire penetration hole as given in this Service Bulletin. If additional cracking is found at the 0.50 inch or standoff/tooling holes, contact Boeing for repair instructions. Repair all cracking damage. If no cracking is found at the 1.04 inch nominal diameter wire penetration hole, either accomplish the preventative modification as given in this service bulletin, or restore access, put the airplane back to a serviceable condition and do repeat inspections at the intervals given in Paragraph 1.E., Compliance .
EFFECTIVITY 737-300/400/500 Series Airplanes. Refer to Paragraph 1.A.1 Airplanes, for the list of affected airplanes.
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Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 8 of 159 BOEING SERVICE BULLETIN 737-53A1279
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COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2009-02-06 R1 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.
See Service Bulletin Paragraph 1.E., for compliance information.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, and/or repair procedures given in this service bulletin.
MANPOWER See Service Bulletin Paragraph 1.G., for manpower information.
MATERIAL INFORMATION Operator Supplied Parts/Materials. Refer to Paragraph 2.A., Material - Price and Availability .
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Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 9 of 159 BOEING SERVICE BULLETIN 737-53A1279
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BOEING SERVICE BULLETIN 737-53A1279
ALERT ALERT SEE S-19R
TYPICAL CRACKING AT OUTBOARD AND INBOARD SIDE OF 1.04 INCH NOMINAL DIAMETER WIRE PENETRATION HOLE.
IF NO CRACKING IS FOUND AT THE
1.04 INCH NOMINAL DIAMETER WIRE
PENETRATION HOLE IS FOUND, EITHER
DO REPEAT INSPECTIONS AS GIVEN IN PARAGRAPH I.E. COMPLIANCE, OR
ACCOMPLISH THE PREVENTATIVE
MODIFICATION AS GIVEN IN THIS SERVICE BULLETIN.
INSPECT THE 1.04 INCH
NOMINAL DIAMETER WIRE
PENETRATION HOLE FOR CRACKING.
S-22R S-20R IF CRACKING AT THE 1.04 INCH
NOMINAL DIAMETER WIRE
PENETRATION HOLE IS FOUND, INSPECT THE 0.50 INCH DIAMETER
HOLE AND ALL STANDOFF/TOOLING HOLES BETWEEN STRINGER 19 AND STRINGER 22. IF NO CRACKING IS S-21R FOUND AT THE 0.50 INCH OR
STANDOFF/TOOLING HOLES, REPAIR
CRACKING AT THE WIRE
PENETRATION HOLE AS GIVEN IN UP THIS SERVICE BULLETIN. IF
ADDITIONAL CRACKING IS FOUND INBD < AT THE 0.50 INCH OR
STANDOFF/TOOLING HOLES,
CONTACT BOEING FOR REPAIR INSTRUCTIONS.
VIEW LOOKING FORWARD (TYPICAL FRAME SECTION) RIGHT SIDE SHOWN 1339121
LEFT SIDE OPPOSITE Original Issue: December 18, 2007 Revision 1: September 02, 2011 737-53A1279
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 159
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1279 Original Issue: December 18, 2007 Revision 1: September 02, 2011 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Forward Cargo Bay Stringer 19 to Stringer 21
- Frames and Frame Reinforcements - Inspection, Repair and Preventative Modification at Wire Penetration Hole
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 737-300 Series Airplanes, Line numbers 1001-3130.-1 737-400 Series Airplanes, Line numbers 1487-3132.-2 737-500 Series Airplanes, Line numbers 1718-3116.-3 Airplane Models:
737-300, 737-400, 737-500 GroupVariable Number 2PJ301 - PJ302 2PJ551 - PJ561 2PJ601 - PJ615
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GroupVariable Number 2PJ811 2PJ816 - PJ817 1PM381 - PM399 1PM401 - PM417 1PM541 - PM550 2PM551 - PM564 1PP001 - PP054 1PP101 - PP169 1PP181 - PP199 1PP201 - PP205 1PP221 1PP231 - PP243 1PP281 - PP286 1PP301 - PP305 1PP351 - PP353 1PP376 - PP384 1PP391 - PP393 1PP401 - PP440 1PP471 - PP475 1PP501 - PP522 1PP631 - PP634 1PP651 - PP652 1PP671 - PP699 1PP701 - PP733 1PP771 - PP779 1PP801 - PP808 1PP821 - PP827 1PP831 - PP848 1PP851 - PP852 1PP861 - PP877 1PP891 - PP899 1PP901 - PP936 1PP946 - PP948
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Original Issue: December 18, 2007 737-53A1279Revision 1: September 02, 2011 12 of 159 BOEING SERVICE BULLETIN 737-53A1279