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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1347 Original Issue: December 09, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Stations 559, 578 and 601 - Body Frame and Overwing Stub Beam Inspection and Repair 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 © 2015 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Unpublished Work.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: December 09, 2015 737-53A1347 1 of 110
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 2 of 110 BOEING SERVICE BULLETIN 737-53A1347
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Table of Contents
S u m m a r y5
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 3 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F . A p p r o v a l ............................................... 2 1 G. Manpower .............................................. 2 1 H. Weight and Balance Changes .................................... 2 4 I. Electrical Load Data ......................................... 2 4 J . R e f e r e n c e s .............................................. 2 4
1. Existing Data: ......................................... 2 4
2. Data Supplied with this Service Bulletin: ........................... 2 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 5 K. Publications Affected ........................................ 2 5 L. Interchangeability and Intermixability of Parts ........................... 2 5 M. Software Accomplishment Summary ................................ 2 5
2. MATERIAL INFORMATION ........................................ 2 7 A. Material - Price and Availability ................................... 2 7 B. Industry Support Information .................................... 2 7 C. Parts Necessary for Each Airplane ................................. 2 7 1 . K i t s / P a r t s : ........................................... 2 7
2. Parts and Materials Supplied by the Operator: ........................ 2 8
3. Parts Modified and Reidentified: ............................... 3 0
4. Parts Removed and Not Replaced: .............................. 3 0 D. Parts Necessary to Change Spares ................................. 3 0 E. Special Tooling - Price and Availability ............................... 3 0 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 3 FIGURE 1: LEFT OVERWING STUB BEAM AT STA 559, STA 578 AND STA 601 - HFEC INSPECTION .................................................. 3 8 FIGURE 2: RIGHT OVERWING STUB BEAM AT STA 559, STA 578 AND STA 601 - HFEC INSPECTION .................................................. 4 3 FIGURE 3: LEFT OVERWING STUB BEAM AT STA 578 - REMOVAL AND HFEC OPEN HOLE INSPECTION .......................................... 4 8 FIGURE 4: RIGHT OVERWING STUB BEAM AT STA 578 - REMOVAL AND HFEC OPEN HOLE INSPECTION .......................................... 5 3 FIGURE 5: LEFT OVERWING STUB BEAM AT STA 578 - INSTALLATION .............. 5 8 FIGURE 6: RIGHT OVERWING STUB BEAM AT STA 578 - INSTALLATION .............. 6 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 3 of 110 BOEING SERVICE BULLETIN 737-53A1347
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FIGURE 7: LEFT FRAME AT STA 559, STA 578 AND STA 601 FROM STRINGER S-16L AND OVERWING STUB BEAMS AT STA 559 AND 601 FROM S-17L DOWN TO THE WING CENTER FUEL TANK UPPER PANEL - DETAILED INSPECTION ...................... 8 0 FIGURE 8: RIGHT FRAME AT STA 559, STA 578 AND STA 601 FROM STRINGER S-16R AND OVERWING STUB BEAMS AT STA 559 AND 601 FROM S-17R DOWN TO THE WING CENTER FUEL TANK UPPER PANEL - DETAILED INSPECTION ...................... 8 5 FIGURE 9: LEFT FRAME INNER CHORD BETWEEN THE CREASE BEAM WEB AND THE WING CENTER FUEL TANK UPPER PANEL AT STA 578 - DETAILED INSPECTION OPTION 1 ..... 9 0 FIGURE 10: RIGHT FRAME INNER CHORD BETWEEN THE CREASE BEAM WEB AND THE WING CENTER FUEL TANK UPPER PANEL AT STA 578 - DETAILED INSPECTION OPTION 1 . 92 FIGURE 11: LEFT FRAME INNER CHORD BETWEEN THE CREASE BEAM WEB AND THE WING CENTER FUEL TANK UPPER PANEL AT STA 578 - HFEC INSPECTION OPTION 2 ........ 9 4 FIGURE 12: RIGHT FRAME INNER CHORD BETWEEN THE CREASE BEAM WEB AND THE WING CENTER FUEL TANK UPPER PANEL AT STA 578 - HFEC INSPECTION OPTION 2 . . 96 FIGURE 13: POST-REPLACEMENT HFEC INSPECTION - LEFT OVERWING STUB BEAM AT STA 578 .................................................. 9 8 FIGURE 14: POST-REPLACEMENT HFEC INSPECTION - RIGHT OVERWING STUB BEAM AT STA 578 ................................................. 1 0 1 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 1: INSPECTION OF THE FRAMES AND OVERWING STUB BEAMS AT STA 559, STA 578 AND STA 601 AND REPLACEMENT OF THE OVERWING STUB BEAM AT STA 578, LEFT AND RIGHT SIDES ( R E Q U I R E D M I N I M U M F O R S A F E T Y ) . .......................... 1 0 4 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 2: INSPECTION OF THE OVERWING STUB BEAM UPPER CHORD AT STA 578 - POST REPAIR OVERWING STUB
BEAM REPLACEMENT HFEC INSPECTION, LEFT AND RIGHT SIDES (REQUIRED MINIMUM F O R S A F E T Y )........................................ 1 0 7 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 3: DETAILED OR HFEC
INSPECTION OF THE FRAME INNER CHORD BETWEEN THE CREASE BEAM WEB AND THE WING CENTER FUEL TANK UPPER PANEL AT STA 578, LEFT AND RIGHT SIDES (RECOMMENDED ECONOMIC INSPECTION) ....................... 1 0 8 APPENDIX D: PART DEMAND INTENT .................................. 1 1 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 4 of 110 BOEING SERVICE BULLETIN 737-53A1347
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1347Original Issue: December 09, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Stations 559, 578 and 601 - Body Frame and Overwing Stub Beam Inspection and Repair
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 the left and right side overwing stub beam upper chords for any crack emanating from the rivet location common to the crease beam inner chord and the overwing stub beam upper chords at Body Stations (STA) 559, 578 and 601. High flight cycle fatigue stresses from both pressurization and maneuver loads can cause cracks in the upper chord of the overwing stub beam at STA 578 which could adversely affect the structural integrity and result in possible decompression of the airplane.
Periodic repeat inspections and the replacement of any cracked overwing stub beam at STA 578 will reduce the possibility of undetected fatigue cracks occurring in the adjacent frame and overwing stub beam structure at Body Stations (STA) 559, 578 and 601.
Boeing has received ten reports from four operators of cracks in the upper chord of the overwing stub beams at STA 578 emanating from the rivet location common to the crease beam inner chord and the overwing stub beam upper chord on 737-400 airplanes. At the time of release of this service bulletin there have been no reports of any crack in the upper chords of the overwing stub beams at STA 559 or STA 601.
The earliest reported crack in an overwing stub beam upper chord occurred on an airplane with 31,843 flight cycles. Seven airplanes had a severed overwing stub beam upper chord on either the left or right side and two airplanes had severed overwing stub beam upper chords on the left and right side.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 5 of 110
In addition, this service bulletin gives instructions for a recommended economic inspection for any crack in the inboard frame chord between the crease beam web and the wing center fuel tank upper panel at STA 578 which could prevent costly repairs in the future should any cracks occur. The cause of the cracks in the inboard chord of the frame between the crease beam web and the wing center fuel tank upper panel at STA 578 is due to pull-up stresses and is similar to the frame cracks at STA 601 addressed by an economic inspection and repair in Boeing Service Bulletin 737-53A1254, Revision 2. Boeing has received eight reports of cracks in the inboard chord of the frame between the crease beam web and the wing center fuel tank upper panel at STA 578 on 737-400 airplanes. Three airplanes had cracks on either the left or right side and one airplane had cracks on both the left and right side.
Boeing Service Related Problem (SRP) 737-SRP-53-0411 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 53-14006 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/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 35005-305RS)
1. Do a surface High Frequency Eddy Current (HFEC) inspection of the overwing stub beam upper chord on the left and right sides for any crack at Body Stations (STA) 559, 578 and 601.
a. If no crack is found, repeat the surface HFEC inspection in accordance with Paragraph 1.E., Compliance.
b. If any crack is found at STA 559 or STA 601, contact The Boeing Company for repair instructions and do the repair.
c. If any crack is found at STA 578:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 6 of 110 BOEING SERVICE BULLETIN 737-53A1347
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(1) Do a detailed inspection for any crack in the frames and adjacent structure at STA 559, STA 578 and STA 601 from stringer S-16 down to the wing center fuel tank upper panel.
(a) If any crack is found, contact The Boeing Company for repair instructions and do the repair.
(b) If no crack is found, replace the cracked overwing stub beam at STA 578.
(2) Do the post-replacement inspection of the overwing stub beam replacement at STA 578 in accordance with Paragraph 1.E., Compliance.
(a) If any crack is found, contact The Boeing Company for repair instructions and do the repair.
(b) If no crack is found, repeat the post-replacement inspection for any crack in accordance with Paragraph 1.E., Compliance.
Operators have the option to do a detailed inspection or a surface HFEC inspection of the frame inner chord between the crease beam web and wing center fuel tank upper panel at STA 578 for any crack. The permitted number of flight cycles between inspections is increased if a surface HFEC inspection is done. If any crack is found, contact The Boeing Company for repair instructions and do the repair. This inspection is not mandatory for safety. It is an optional economic inspection to find any crack in the inner frame chord which could prevent costly repairs in the future should any cracks occur.
EFFECTIVITY All 737-400 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.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection, repair and modification procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operators are encouraged to complete the survey provided in APPENDIX D of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Boeing Supplied Kits/Parts.
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: December 09, 2015 737-53A1347 7 of 110 BOEING SERVICE BULLETIN 737-53A1347
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BOEING SERVICE BULLETIN 737-53A1347
ALERT ALERT STA 559 STA 639 FRAME ∞ D (TYPICAL)
STA HATCH ESCAPE 639 S-16L
CREASE BEAM
INNER CHORD
LONGITUDINAL
FLOOR BEAM
STUB BEAM AT STA 601
WING CENTER FUEL
TANK UPPER PANEL
STUB BEAM AT STA 578 STUB BEAM AT STA 559 $ LBL 45.5 2331075
LEFT SIDE SHOWN, RIGHT SIDE SIMILAR Original Issue: December 09, 2015 Export Controlled ECCN: 9E991 - BOEING 737-53A1347 PROPRIETARY - Copyright @ Unpublished Work - See page 1 for details. 8 of 110
BOEING SERVICE BULLETIN 737-53A1347
ALERT ALERT FRAME
DO A HFEC INSPECTION OF THE STUB BEAM UPPER
CHORD AT THE CREASE BEAM INNER CHORD FASTENER ATTACHMENT AT STA 559, STA 578 AND STA S-16L- 601 FOR ANY CRACK S-17L
STUB BEAM STA 559
FRAME A-A S-16L CRACK (TYPICAL) S-17L
STUB BEAM FRAME S-16l
CREASE BEAM LONGITUDINAL
INNER CHORD FLOOR BEAM (TYPICAL) (TYPICAL) S-17L - WING CENTER FUEL 000 0 o TANK UPPER PANEL (TYPICAL)
STUB BEAM STA 601 LEFT SIDE SHOWN, RIGHT SIDE SIMILAR C-C INBD 2367924 Original Issue: December 09, 2015 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1347 Work - See page 1 for details. 9 of 110
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 10 of 110 BOEING SERVICE BULLETIN 737-53A1347
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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1347 Original Issue: December 09, 2015 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Body Stations 559, 578 and 601 - Body Frame and Overwing Stub Beam Inspection and Repair
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 D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP All 737-400 airplanes.-1 Airplane Models:
737-400 GroupVariable Number 1PJ301 - PJ302 1PJ551 - PJ561 1PJ601 - PJ615 1PJ811 1PJ816 - PJ817 1PM551 - PM564 1PV001 - PV055 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 11 of 110
GroupVariable Number 1PV201 - PV209 1PV226 - PV229 1PV231 - PV237 1PV271 - PV272 1PV281 - PV287 1PV296 1PV301 - PV302 1PV351 1PV356 - PV357 1PW001 - PW054 1PW061 - PW068 1PW072 1PW086 - PW088 1PW091 - PW094 1PW101 - PW102 1PW106 1PW111 - PW120 1PW156 - PW157 1PW161 - PW171 1PW201 - PW252 1PW261 - PW268 1PW271 - PW276 1PW278 1PW281 - PW293 1PW296 1PW301 - PW327 1PW401 - PW408 1PW411 - PW418 1PW421 - PW424 1PW431 - PW435 1PW441 - PW450 1PW461 - PW467 1PW501 - PW504 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 09, 2015 737-53A1347 12 of 110 BOEING SERVICE BULLETIN 737-53A1347