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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1319 Original Issue: April 04, 2011 Revision 2: April 04, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Crown Skin Lap Joint - Inspection for Lower Row Cracks at Stringer S-4, Between Body Station 360 and Body Station 1016 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 © 2011 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Unpublished Work.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: April 04, 2011 737-53A1319Revision 2: April 04, 2014 1 of 62
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 2 of 62 BOEING SERVICE BULLETIN 737-53A1319
ALERTALERT
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 6 B. Concurrent Requirements ...................................... 1 6 C. Reason ................................................ 1 6 D. Description .............................................. 1 7 E. Compliance .............................................. 1 8 F. Approval ............................................... 2 5 G. Manpower .............................................. 2 6 H. Weight and Balance Changes .................................... 2 7 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 M. Software Accomplishment Summary ................................ 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 ....................... 2 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1 A. GENERAL INFORMATION ..................................... 3 1 B. WORK INSTRUCTIONS ....................................... 3 3 FIGURE 1: EXTERNAL INSPECTION ................................... 4 2 FIGURE 2: INTERNAL INSPECTION ................................... 4 4 FIGURE 3: CONFIRMING A CRACK INDICATION ............................ 4 8 FIGURE 4: FIGURE DELETED AT REVISION 2 ............................. 5 2 FIGURE 5: INSPECTION ZONES [Group 1-2, 4-7] ............................ 5 3 FIGURE 6: INSPECTION ZONES [Group 3] ................................ 5 6 FIGURE 7: INSPECTION ZONES ..................................... 5 7 FIGURE 8: INTERNAL GENERAL VISUAL INSPECTION - LOWER SKIN PANEL AT S-4R, BS 908 TO BS 1016 [Group 1, 4, 6] ...................................... 6 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 3 of 62 BOEING SERVICE BULLETIN 737-53A1319
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 4 of 62 BOEING SERVICE BULLETIN 737-53A1319
ALERTALERT
BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-53A1319Original Issue: April 04, 2011 Revision 2: April 04, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Crown Skin Lap Joint - Inspection for Lower Row Cracks at Stringer S-4, Between Body Station 360 and Body Station 1016 This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive AD 2011-08-51 is related to this service bulletin.
The Federal Aviation Administration (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.
More work is necessary on the airplanes inspected in accordance with the Original Issue or Revision 1 of this service bulletin.
Additional work requirements are in Paragraph 1.E., Compliance, Tables 3, 4, 5, and 6.
Optional repeat inspection intervals are in Paragraph 1.E., Compliance, Table 2.
REASON FOR REVISION This revision is sent to define new groups, provide new compliance tables, and add more inspections. In addition, the second external inspection in Figure 4 is deleted.
The data given in Information Notice 737-53A1319 IN-01 is included in this revision.
These sections were changed:
1. In Summary, changed Background, Action, Compliance, Industry Support Information, and Summary Figure.
2. In Paragraph 1.A.1., Airplanes, added Service Bulletin Index and defined new Groups.
3. In Paragraph 1.C., Reason, added fleet findings, Widespread Fatigue Damage (WFD) statement, Service Related Problem (SRP) number, and Fleet Team Digest (FTD) number.
4. In Paragraph 1.D., Description, changed to agree with Compliance and Work Instructions sections and added Maintenance Zone tables.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 5 of 62
5. In Paragraph 1.E., Compliance - added Airworthiness Directive (AD) effective date, inspection exceptions, new compliance requirements, and compliance tables.
6. In Paragraph 1.F., Approval, changed alternative method of compliance (AMOC) approval statement.
7. In Paragraph 1.G., Manpower, changed Manpower tables.
8. In Paragraph 1.J., References, changed Existing Data.
9. In Paragraph 1.M., Software Accomplishment Summary, added software accomplishment section.
10. In Paragraph 2.B., Industry Support Information, added warranty statement.
11. In Paragraph 3.A., General Information, changed Notes.
12. In Paragraph 3.B., Work Instructions, changed to agree with Description and Compliance sections.
13. Figure 1, added locator and changed Non-Destructive Testing (NDT) from Figure to Procedure to agree with the 737 NDT Manual.
14. Figure 2, added locator, changed illustration, and added inspection note for locations obstructed by the internal structures.
15. Figure 3, added locator, changed illustration, added inspection note for locations obstructed by the internal structures and removed the optional open hole rotary probe inspection.
16. Figure 4, deleted figure because Boeing has determined that the second external inspection is no longer required.
17. Figure 5, added Group heading.
18. Figures 6-7, added new figures for inspection zones.
19. Figure 8, added new figure for internal general visual inspection.
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 important changes.
REVISION HISTORY April 04, 2011Original Issue:
April 08, 2011Revision 1:
April 04, 2014Revision 2:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 6 of 62 BOEING SERVICE BULLETIN 737-53A1319
ALERTALERT
Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1319Original Issue: April 04, 2011 Revision 2: April 04, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Crown Skin Lap Joint - Inspection for Lower Row Cracks at Stringer S-4, Between Body Station 360 and Body Station 1016
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 A 737-300 airplane, outside of the effectivity of Service Bulletin (SB) 737-53A1255, experienced a rapid decompression when the lap joint at stringer S-4L between BS 664 - BS 727 cracked and opened up. Investigation shows that the cracks were caused by fatigue cracks in the lower skin at the lower row of fasteners in the lap joint. The airplane had 39,781 total flight cycles and 48,740 total flight hours. This service bulletin gives instructions to inspect the lower row of fasteners at stringer S-4R and S-4L, from BS 360 to BS 908 for cracks in the lower skin of the lap joint. If cracks at this location go undetected, the cracks could link up, resulting in an uncontrolled decompression.
After the original issue of this service bulletin, Non-Destructive Testing (NDT) inspections have resulted in additional fleet findings in the skin at the lap joint lower fastener row. Fourteen (14) aircraft were reported with crack indications between 38,222 - 44,784 total flight cycles and 46,822 - 54,434 total hours.
Further investigation into these reports of cracks in the lower skin at the lap joint lower row fastener hole have identified small cracks and cracks from scratches. There were nine (9) findings with scratch cracks. Scratch cracks form in the lower skin at the lap joint lower fastener row, local to the hole, but may not intersect the hole.
Internal crack confirmation common to doublers and tear straps using hole probe inspections have been removed from this service bulletin because scratch cracks may not intersect the fastener hole.
Airplanes prior to Line Number 2553 are covered by Service Bulletin (SB) 737-53A1255. This SB covers airplanes from Line Number 2553 to 3132.
The lap splice - fuselage lower fastener hole in the lower skin has been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
Boeing Service Related Problem (SRP) 737-SRP-53-0330 is related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 7 of 62
Boeing Fleet Team Digest (FTD) 737 FTD 53-09004 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 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 NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION This service bulletin gives instructions to do as follows:
1. Part 1: (Option 1) External eddy current inspection at S-4L and S-4R, BS 360 to BS 908 for cracks, excluding BS 540 to BS 727E for Group 3 airplanes.
Or Part 1: (Option 2) Internal detailed and eddy current inspections at S-4L and S-4R, BS 360 to BS 908 for cracks, excluding BS 540 to BS 727E for Group 3 airplanes.
2. Part 2: One-time internal detailed and eddy current inspections at S-4L and S-4R, BS 360 to BS 908 for cracks, excluding BS 540 to BS 727E for Group 3 airplanes.
3. Group 2-3, 5, 7:
Part 3: One-time internal detailed and eddy current inspections at S-4R, BS 908 to BS 1016 for cracks.
4. Group 2-3, 5, 7:
Part 4: (Option 1) External eddy current inspection at S-4R, BS 908 to BS 1016 for cracks.
Or Part 4: (Option 2) Internal detailed and eddy current inspections at S-4R, BS 908 to BS 1016 for cracks.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 8 of 62 BOEING SERVICE BULLETIN 737-53A1319
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5. Group 1, 4, 6:
Part 5: Internal general visual inspection of lower skin panel at S-4R, BS 908 to BS 1016 for open or closed pockets.
EFFECTIVITY 737-300, 737-400, and 737-500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (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.
Federal Aviation Administration (FAA) Airworthiness Directive AD 2011-08-51 is related to this service bulletin.
The effective date of AD 2011-08-51 is June 2, 2011.
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.
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: April 04, 2011 737-53A1319Revision 2: April 04, 2014 9 of 62 BOEING SERVICE BULLETIN 737-53A1319
ALERTALERT
BOEING SERVICE BULLETIN 737-53A1319
ALERT ALERT STA 1016 STA 908 STA 540 STA 360 UPPER SKIN AND DOUBLER S-4R • S-4L * * SAUR
LOWER SKIN
TEAR STRAP S-4L/R
INSPECT LAP JOINT BETWEEN STA 360 AND STA 908 AT S-4L AND S-4R AND BETWEEN STA 908 AND STA 1016 AT S-4R
CRACKS SHOWN IN THE LOWER SKIN
AT THE LOWER ROW OF FASTENERS TYPICAL LAP JOINT CONFIGURATION 2068118 Original Issue: April 04, 2011 Revision 2: April 04, 2014 Export Controlled ECCN: 9E991 - BOEING 737-53A1319 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 62
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1319 Original Issue: April 04, 2011 Revision 2: April 04, 2014 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Crown Skin Lap Joint - Inspection for Lower Row Cracks at Stringer S-4, Between Body Station 360 and Body Station 1016
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 This service bulletin is for the airplane(s) shown below.
Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 737-300 airplanes with specific inspection zones S-4R and S-4L, BS 360 to BS 908 and internal general visual inspection for open or closed pockets at S-4R, BS 908 to BS 1016.
-1 737-300 airplanes with specific inspection zones S-4R and S-4L, BS 360 to BS 908 and S-4R, BS 908 to BS 1016.
-2 737-300 airplanes with specific inspection zones S-4R and S-4L, BS 360 to BS 540 and BS 727E to BS 908 and S-4R, BS 908 to BS 1016.
-3 737-400 airplanes with specific inspection zones S-4R and S-4L, BS 360 to BS 908 and internal general visual inspection for open or closed pockets at S-4R, BS 908 to BS1016.
-4 737-400 airplanes with specific inspection zones S-4R and S-4L, BS 360 to BS 908 and S-4R, BS 908 to BS 1016.
-5 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 11 of 62
DESCRIPTIONCONFIGURATIONGROUP 737-500 airplanes with specific inspection zones S-4R and S-4L, BS 360 to BS 908 and internal general visual inspection for open or closed pockets at S-4R, BS 908 to BS 1016.
-6 737-500 airplanes with specific inspection zones S-4R and S-4L, BS 360 to BS 908 and S-4R, BS 908 to BS 1016.
-7 Airplane Models:
737-300, 737-400, 737-500 GroupVariable Number 5PJ552 - PJ559 4PJ560 - PJ561 4PJ601 - PJ615 4PJ811 4PJ816 - PJ817 2PM543 - PM550 2PP518 - PP520 1PP876 - PP877 2PQ297 - PQ299 2PQ345 - PQ348 2PQ370 - PQ373 2PQ391 - PQ393 1PQ394 - PQ395 2PQ408 - PQ410 2PQ414 1PQ415 - PQ418 2PQ431 - PQ438 2PQ447 1PQ448 1PQ451 1PQ454 2PQ473 - PQ475 2PQ772 2PQ933 - PQ935 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 04, 2011 737-53A1319Revision 2: April 04, 2014 12 of 62 BOEING SERVICE BULLETIN 737-53A1319