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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1322 Original Issue: November 05, 2012 ATA System: 5312 5311 SUBJECT: FUSELAGE - Stringers and Other Longitudinal Members - Stringer Splices and Butt Straps at Body Station 360 and Body Station 908, Stringer S-10L to S-10R - Inspection and Replacement 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 © 2012 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Unpublished Work.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: November 05, 2012 737-53A1322 1 of 229
7.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 2 of 229 BOEING SERVICE BULLETIN 737-53A1322
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BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 2 5 B. Concurrent Requirements ...................................... 2 5 C. Reason ................................................ 2 5 D. Description .............................................. 2 6 E. Compliance .............................................. 2 7 F. Approval ............................................... 4 2 G. Manpower .............................................. 4 3 H. Weight and Balance Changes .................................... 4 8 I. Electrical Load Data ......................................... 4 8 J. References .............................................. 4 8
1. Existing Data: ......................................... 4 8
2. Data Supplied with this Service Bulletin: ........................... 4 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 9 K. Publications Affected ........................................ 5 0 L. Interchangeability and Intermixability of Parts ........................... 5 0 M. Software Accomplishment Summary ................................ 5 0
2. MATERIAL INFORMATION ........................................ 5 1 A. Material - Price and Availability ................................... 5 1 B. Industry Support Information .................................... 5 1 C. Parts Necessary for Each Airplane ................................. 5 1
1. Kits/Parts ............................................ 5 1
2. Parts and Materials Supplied by the Operator ........................ 5 3
3. Parts Modified and Reidentified ................................ 5 4
4. Parts Removed and Not Replaced .............................. 5 4 D. Parts Necessary to Change Spares ................................. 5 5 E. Special Tooling - Price and Availability ............................... 5 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 7 A. GENERAL INFORMATION ..................................... 5 7 B. WORK INSTRUCTIONS ....................................... 5 8 FIGURE 1: STA 360 AND STA 908, ZONE A AND B (S-10L TO S-10R) - STRINGER SPLICE AND BUTT STRAP - INTERNAL DETAILED INSPECTION [Group 2-4] ................. 7 0 FIGURE 2: STA 360 AND STA 908, ZONE A (S-5L TO S-3L, S-3R TO S-5R) OPTION 1 - BUTT STRAP - EDDY CURRENT INSPECTION [Group 2-4] ......................... 7 4 FIGURE 3: STA 360 AND STA 908, ZONE A (S-5L TO S-3L, S-3R TO S-5R) OPTION 2 - BUTT STRAP - EDDY CURRENT INSPECTION [Group 2-4] ......................... 7 9 FIGURE 4: STA 360 AND STA 908, ZONE B (S-10L TO S-5L, S-3L TO S-3R, S-5R TO S-10R) - BUTT STRAP - INTERNAL EDDY CURRENT INSPECTION [Group 2-4] ............. 8 4 FIGURE 5: STA 908, ZONE A AND B (S-10L TO S-10R) - STRINGER SPLICE AND BUTT STRAP - INTERNAL DETAILED INSPECTION [Group 5-6] ...................... 9 0 FIGURE 6: STA 908, ZONE A (S-5L TO S-3L, S-3R TO S-5R) OPTION 1 - BUTT STRAP - INTERNAL EDDY CURRENT INSPECTION [Group 5-6] ......................... 9 4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 3 of 229 BOEING SERVICE BULLETIN 737-53A1322
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FIGURE 7: STA 908, ZONE A (S-5L TO S-3L, S-3R TO S-5R) OPTION 2 - BUTT STRAP - EDDY CURRENT INSPECTION [Group 5-6] ................................... 9 7 FIGURE 8: STA 908, ZONE B (S-10L TO S-5L, S-3L TO S-3R, S-5R TO S-10R) - BUTT STRAP - INTERNAL EDDY CURRENT INSPECTION [Group 5-6] ........................ 1 0 0 FIGURE 9: STA 360 AND STA 908 (S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 2, Configuration 1-4] ................... 1 0 5 FIGURE 10: STA 360 AND STA 908 (S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 2, Configuration 5-8] ................... 1 1 2 FIGURE 11: STA 360 AND STA 908 (S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 3, Configuration 1] .................... 1 1 5 FIGURE 12: STA 360 AND STA 908 (S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 3, Configuration 2; Group 4] ............... 1 2 1 FIGURE 13: STA 908 (S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 5, Configuration 1-4] ...................... 1 2 4 FIGURE 14: STA 908 (S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 5, Configuration 5-8] ...................... 1 2 9 FIGURE 15: STA 908(S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 6, Configuration 1] ....................... 1 3 2 FIGURE 16: STA 908 (S-5L TO S-3L, S-3R TO S-5R) - BUTT STRAP - FASTENER REMOVAL AND REINSTALLATION [Group 6, Configuration 2] ....................... 1 3 6 FIGURE 17: STA 360 (S-5L TO S-6R, S-8R TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 2, Configuration 1-4] ....................................... 1 3 9 FIGURE 18: STA 908 (S-10L TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 2, Configuration 1-4; Group 5, Configuration 1-4] ............................... 1 5 0 FIGURE 19: STA 360 (S-5L TO S-6R, S-8R TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 2, Configuration 5-8] ....................................... 1 5 9 FIGURE 20: STA 908 (S-10L TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 2, Configuration 5-8; Group 5, Configuration 5-8] ............................... 1 6 8 FIGURE 21: STA 360 (S-5L TO S-6R, S-8R TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 3, Configuration 1] ........................................ 1 7 6 FIGURE 22: STA 908 (S-10L TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 3, 6, Configuration 1 ] ................................................ 1 8 6 FIGURE 23: STA 360 (S-5L TO S-6R, S-8R TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 3, Configuration 2; Group 4] ................................... 1 9 5 FIGURE 24: STA 908 (S-10L TO S-10R) - STRINGER SPLICE - REPLACEMENT [Group 3, Configuration 2; Group 4; Group 6, Configuration 2] ............................ 2 0 4 APPENDIX A: STRINGER SPLICE DATA .................................. 2 1 3 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 4 of 229 BOEING SERVICE BULLETIN 737-53A1322
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1322Original Issue: November 05, 2012 ATA System: 5312 5311 SUBJECT: FUSELAGE - Stringers and Other Longitudinal Members - Stringer Splices and Butt Straps at Body Station 360 and Body Station 908, Stringer S-10L to S-10R - Inspection and Replacement
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 Accomplishment of the inspections and replacement given in this Service Bulletin (SB) will make sure that stringer splice and butt strap cracks are found and repaired. Fuselage skin vertical chem-mill step cracks can interact with stringer splice cracks and butt strap cracks. The interaction of cracking with the three structural elements may result in the airplane not being able to sustain limit load requirements and potential uncontrolled decompression.
Boeing received fleet reports of 197 stringer splice cracks at Body Station STA 360 and STA 908, between Stringer S-10L and S-10R, 16 butt strap cracks between S-5L and S-3L, S-3R and S-5R and 12 vertical chem-mill fuselage skin cracks at butt joints as addressed in SB 737-53A1210 and SB 737-53A1234. Additionally, Boeing received one report of all three structural elements cracking on the same airplane during a maintenance inspection.
Analysis by Boeing indicates that cracking of the stringer splices is attributed to airplane fatigue loads. Cracking of the butt strap at STA 360 and STA 908 is attributed to fatigue loading from S-4 lap joint.
Boeing Service Related Problem (SRP) 737-SRP-53-0362 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., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 5 of 229
ReferenceAffectedPlanning Data 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 YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Group 1:
On Group 1 airplanes, contact Boeing to get instructions for the inspection, and/or repair for this SB 737-53A1322 Original Issue, and do the work instructed by Boeing.
Group 2-6:
Do internal detailed inspections of the stringer splices and the butt straps for cracks. If any crack is found in the stringer splice, remove and replace with a new splice. If any crack is found in the butt strap, contact Boeing for skin inspections and repair instructions and do the work instructed by Boeing. If no crack is found, continue repeat inspections in accordance with Paragraph 1.E., Compliance.
Do internal High Frequency Eddy Current (HFEC) surface inspections, internal Low Frequency Eddy Current (LFEC) inspections and HFEC open hole rotary probe inspections of the butt straps for cracks. If any crack is found in the butt strap, contact Boeing for skin inspections and repair instructions and do the work instructed by Boeing. If no crack is found, continue repeat inspections in accordance with Paragraph 1.E., Compliance.
If no crack is found, close access and put the airplane back to a serviceable condition.
Group 2, Configuration 5-8; Group 3, Configuration 2; Group 5, Configuration 5-8; Group 6, Configuration 2:
Economic Consideration: For airplanes that do not have the lap modification accomplished in accordance with SB 737-53A1177, Boeing recommends accomplishing the inspections in accordance with SB 737-53A1322 Original Issue while SB 737-53A1177 lap modification is being accomplished.
EFFECTIVITY 737-100/-200/-200C/-300/-400/-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 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.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 6 of 229 BOEING SERVICE BULLETIN 737-53A1322
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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 Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 7 of 229 BOEING SERVICE BULLETIN 737-53A1322
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BOEING SERVICE BULLETIN 737-53A1322
ALERT ALERT
DO INTERNAL DETAILED INSPECTIONS OF THE STRINGER SPLICES AND THE BUTT STRAPS FOR CRACKS AT BODY STATION 360 AND BODY STATION 908, S-10L TO S-10R.
DO EDDY CURRENT INSPECTIONS OF THE BUTT STRAPS FOR CRACKS AT BODY STATION 360 AND BODY STATION 908, S-10L TO S-10R.
FOR ZONE A (S-5L TO S-3L, S-3R TO S-5R):
OPTION 1 - DO INTERNAL HIGH FREQUENCY EDDY CURRENT SURFACE INSPECTIONS,
INTERNAL LOW FREQUENCY EDDY CURRENT INSPECTIONS OF THE BUTT STRAPS FOR
CRACKS, AND DO A HIGH FREQUENCY EDDY CURRENT OPEN HOLE ROTARY PROBE INSPECTION AT ONE (1) LOCATION OF THE BUTT STRAP FOR CRACKS.
OPTION 2 - DO INTERNAL HIGH FREQUENCY EDDY CURRENT SURFACE INSPECTIONS,
INTERNAL LOW FREQUENCY EDDY CURRENT INSPECTIONS AND HIGH FREQUENCY
EDDY CURRENT OPEN HOLE ROTARY PROBE INSPECTIONS OF THE BUTT STRAPS FOR CRACKS.
FOR ZONE B (S-10L TO S-5L, S-3L TO S-3R, S-5R TO S-10R):
DO INTERNAL HIGH FREQUENCY EDDY CURRENT SURFACE INSPECTIONS AND
INTERNAL LOW FREQUENCY EDDY CURRENT INSPECTIONS OF THE BUTT STRAPS
FOR CRACKS STA 908 STA 360 S-10R 000000000000 S-10L 2118578 Original Issue: November 05, 2012 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1322 Work - See page 1 for details. 8 of 229
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1322 Original Issue: November 05, 2012 ATA System: 5312 5311 SUBJECT: FUSELAGE - Stringers and Other Longitudinal Members - Stringer Splices and Butt Straps at Body Station 360 and Body Station 908, Stringer S-10L to S-10R - Inspection and Replacement
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 airplanes shown below.
Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 737-100/-200/-200C Airplane line numbers 1-291.-1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 9 of 229
DESCRIPTIONCONFIGURATIONGROUP 737-200 Airplane line numbers 292-519.-2 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039.
1 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and preventive modification in accordance with SB 737-53-1076 but have not accomplished SB 737-53A1039.
2 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and preventive modification in accordance with SB 737-53A1039 but have not accomplished SB 737-53-1076.
3 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and have not accomplished preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039.
4 Airplanes that have accomplished the preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039 and have not accomplished lap modification in accordance with SB 737-53A1177.
5 Airplanes that have accomplished the preventive modification in accordance with SB 737-53-1076 and have not accomplished modifications in accordance with SB 737-53A1177 and SB 737-53A1039.
6 Airplanes that have accomplished the preventive modification in accordance with SB 737-53A1039 and have not accomplished modifications in accordance with SB 737-53A1177 or SB 737-53-1076.
7 Airplanes that have not accomplished the lap modification in accordance with SB 737-53A1177 and have not accomplished preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039.
8 737-200/-300/-400/-500 Airplane line numbers 520-2552.-3 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177.
1 Airplanes that have not accomplished the lap modification in accordance with SB 737-53A1177.
2 737-300/-400/-500 Airplane line numbers 2553-3132.-4 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 10 of 229 BOEING SERVICE BULLETIN 737-53A1322
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DESCRIPTIONCONFIGURATIONGROUP 737-200C Airplane line numbers 292-519.-5 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039.
1 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and preventive modification in accordance with SB 737-53-1076 but have not accomplished SB 737-53A1039.
2 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and preventive modification in accordance with SB 737-53A1039 but have not accomplished SB 737-53-1076.
3 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177 and have not accomplished preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039.
4 Airplanes that have accomplished the preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039 and have not accomplished lap modification in accordance with SB 737-53A1177.
5 Airplanes that have accomplished the preventive modification in accordance with SB 737-53-1076 and have not accomplished modifications in accordance with SB 737-53A1177 and SB 737-53A1039.
6 Airplanes that have accomplished the preventive modification in accordance with SB 737-53A1039 and have not accomplished modifications in accordance with SB 737-53A1177 or SB 737-53-1076.
7 Airplanes that have not accomplished the lap modification in accordance with SB 737-53A1177 and have not accomplished preventive modifications in accordance with SB 737-53-1076 and SB 737-53A1039.
8 737-200C Airplane line numbers 520-1113.-6 Airplanes that have accomplished the lap modification in accordance with SB 737-53A1177.
1 Airplanes that have not accomplished the lap modification in accordance with SB 737-53A1177.
2 Airplane Models:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 11 of 229 BOEING SERVICE BULLETIN 737-53A1322
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737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 GroupVariable Number 1PA001 - PA022 1PA099 1PA231 - PA232 1PC001 - PC005 1PG001 - PG075 1PG199 1PG201 - PG230 1PG251 - PG255 1PG271 - PG279 1PG301 - PG314 1PG331 - PG332 1PG351 - PG356 1PG375 1PG401 - PG403 1PG431 - PG442 1PG471 - PG475 1PG501 - PG505 1PG571 - PG583 2PG584 - PG586 1PG621 - PG630 1PG651 - PG652 1PG701 - PG705 2PH001 2PH011 - PH013 2PH021 - PH024 1PH701 - PH715 1PH731 - PH732 1PH741 - PH742 2PH743 1PJ001 - PJ002 2PJ003 - PJ006 3PJ007 - PJ009 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: November 05, 2012 737-53A1322 12 of 229 BOEING SERVICE BULLETIN 737-53A1322