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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1350 Original Issue: May 06, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Upper and Lower Corners of Aft Doorways 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 © 2016 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Unpublished Work.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: May 06, 2016 737-53A1350 1 of 123
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 06, 2016 737-53A1350 2 of 123 BOEING SERVICE BULLETIN 737-53A1350
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BLANK PAGE
Table of Contents
S u m m a r y5
1. PLANNING INFORMATION9
A . E f f e c t i v i t y9
1. Airplanes9
2 . S p a r e s A f f e c t e d ........................................ 2 2 B. Concurrent Requirements ...................................... 2 2 C. Reason ................................................ 2 3 D. Description .............................................. 2 3 E. Compliance .............................................. 2 5 F . A p p r o v a l ............................................... 2 9 G. Manpower .............................................. 2 9 H. Weight and Balance Changes .................................... 3 2 I. Electrical Load Data ......................................... 3 2 J . R e f e r e n c e s .............................................. 3 2
1. Existing Data: ......................................... 3 2
2. Data Supplied with this Service Bulletin: ........................... 3 3
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 3 3 K. Publications Affected ........................................ 3 3 L. Interchangeability and Intermixability of Parts ........................... 3 3 M. Software Accomplishment Summary ................................ 3 4
2. MATERIAL INFORMATION ........................................ 3 5 A. Material - Price and Availability ................................... 3 5 B. Industry Support Information .................................... 3 5 C. Parts Necessary for Each Airplane ................................. 3 5 1 . K i t s / P a r t s ............................................ 3 5
2. Parts and Materials Supplied by the Operator ........................ 3 5
3. Parts Modified and Reidentified ................................ 3 5
4. Parts Removed and Not Replaced .............................. 3 5 D. Parts Necessary to Change Spares ................................. 3 5 E. Special Tooling - Price and Availability ............................... 3 5 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 7 A. GENERAL INFORMATION ..................................... 3 7 B. WORK INSTRUCTIONS ....................................... 3 9 FIGURE 1: AFT ENTRY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 5] ............................. 4 8 FIGURE 2: AFT ENTRY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 3] ............................. 5 4 FIGURE 3: AFT ENTRY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 4] ............................. 6 0 FIGURE 4: AFT ENTRY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 6] ............................. 6 6 FIGURE 5: AFT ENTRY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 7] ............................. 7 2 FIGURE 6: AFT ENTRY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 8] ............................. 7 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 06, 2016 737-53A1350 3 of 123 BOEING SERVICE BULLETIN 737-53A1350
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FIGURE 7: AFT GALLEY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 2-4] ............................ 8 4 FIGURE 8: AFT GALLEY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 5-6, 8] .......................... 9 0 FIGURE 9: AFT GALLEY DOORWAY CORNERS - LOW FREQUENCY EDDY CURRENT (LFEC) AND DETAILED INSPECTIONS [Group 7] ............................. 9 6 F I G U R E 1 0 : A F T E N T R Y D O O R W A Y R A I N G U T T E R - R E M O V A L [ G r o u p 4 - 5 , 7 - 8 ] .......... 1 0 2 FIGURE 11: AFT ENTRY DOORWAY RAIN GUTTER - INSTALLATION [Group 4-5, 7-8] ....... 1 0 4 FIGURE 12: AFT ENTRY DOORWAY RAIN GUTTER - REMOVAL [Group 3, 6] ............ 1 0 6 FIGURE 13: AFT ENTRY DOORWAY RAIN GUTTER - INSTALLATION [Group 3, 6] ......... 1 0 8 FIGURE 14: AFT GALLEY DOORWAY RAIN GUTTER - REMOVAL [Group 2-8] ........... 1 1 0 FIGURE 15: AFT GALLEY DOORWAY RAIN GUTTER - INSTALLATION [Group 2-8] ......... 1 1 2 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: AFT ENTRY AND AFT GALLEY DOORWAY CORNERS - INSPECTION AND REPAIR [Group 3-8] ....... 1 1 4 APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 2: AFT GALLEY DOORWAY CORNERS - INSPECTION AND REPAIR. [Group 2] .................... 1 1 7 APPENDIX C: SCUFF PLATE - REMOVAL [Group 2-4] .......................... 1 1 9 APPENDIX D: SCUFF PLATE - INSTALLATION [Group 2-4] ........................ 1 2 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 06, 2016 737-53A1350 4 of 123 BOEING SERVICE BULLETIN 737-53A1350
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1350Original Issue: May 06, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Upper and Lower Corners of Aft Doorways 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 Accomplishment of the work in this service bulletin will make sure that any crack at the corners of the aft entry and aft galley doorway is detected and repaired. If the work given in this service bulletin is not accomplished, a crack in the aft entry or aft galley doorway may go undetected and grow in length. An undetected crack could result in a possible decompression and loss of structural integrity of the airplane.
The cracks are caused by fatigue from cyclic pressurization of the fuselage combined with increased stress concentration due to the proximity of fastener holes to the corners of the doorways. The cracks typically originate at the fastener holes and grow towards the corners of the doorways.
There have been more than 240 reports of skin cracking at the corners of aft entry and aft galley doorways.
Findings have been primarily on the 737-300 but have been reported on the 737-200 and to a lesser extent on the 737-400 and 737-500. Cracks are most common at the lower forward corners and the upper aft corners of the doorways. Where crack lengths have been reported, these lengths range from 0.25 to 4.50 inches. At the time of crack detection the airplanes had accumulated between 26,896 and 73,655 total flight cycles.
Boeing service bulletin 737-53-1149 provides inspection, preventive modification and repair instructions for the upper forward and aft corners of the aft entry and aft galley doorways for all 737-100 and -200 airplanes. Multiple cracks have been reported common to the skin and bear strap at the upper corners of aft doorways on 737 airplanes that are beyond the effectivity of service bulletin 737-53-1149. More reliable Low Frequency Eddy Current (LFEC) inspections have been added to this service bulletin for cracks at the upper corners of the aft doorways for all airplanes within the effectivity of service bulletin 737-53-1149. After accomplishing the inspections in accordance with this service bulletin, operators do not need to accomplish service bulletin 737-53-1149 inspections for the upper corners of the aft doorways.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 06, 2016 737-53A1350 5 of 123
Boeing service bulletin 737-53-1074, Revision 3, provides inspection, preventive modification and repair instructions for the lower forward and aft corners of the aft entry and aft galley doorways for 737-100 and -200 airplanes, line numbers 1 to 1014. Multiple cracks have been reported common to the skin and bear strap at the lower corners of the aft doorways on 737 airplane line numbers 1015 to 3132 that are beyond the effectivity of service bulletin 737-53-1074, Revision 3. More reliable LFEC inspections have been added to this service bulletin for cracks at the lower corners of the aft doorways for all airplanes within the effectivity of service bulletin 737-53-1074, Revision 3. After accomplishing the inspections in accordance with this service bulletin, operators do not need to accomplish service bulletin 737-53-1074, Revision 3 inspections for the lower corners of the aft doorways.
Boeing Service Related Problems (SRP) 737-SRP-53-0389 and 737-SRP-53-0393 are related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 53-11004 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 ChangesYesWeight 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 Group 1:
The Boeing Company endorses the new FAA rules related to Limit of Validity (LOV) and recommends immediate and permanent removal from service of any airplanes upon reaching the LOV, whether or not it is operated under FAA jurisdiction. As such, The Boeing Company no longer provides maintenance instructions for airplanes that have accumulated flight cycles beyond the LOV. Airplanes in Group 1 (line number 1-291) have accumulated flight cycles beyond the LOV of the maintenance program. 14 CFR 121.1115 and 129.115 prohibit operation of an airplane beyond its LOV.
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Original Issue: May 06, 2016 737-53A1350 6 of 123 BOEING SERVICE BULLETIN 737-53A1350
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Group 2:
Remove the scuff plate at the lower corners of the aft galley doorway. If the rain gutter interferes with the Low Frequency Eddy Current (LFEC) inspection, remove it from above the aft galley doorway. At the upper and lower corners of the aft galley doorway, do an external LFEC inspection of the skin assembly and bear strap for any crack around fasteners and do an external detailed inspection of the skin assembly for any crack. If any crack is found in the skin assembly or bear strap, install a repair in accordance with Structural Repair Manual (SRM).
If no crack is found, do the repeat inspections at the intervals given in Paragraph 1.E., Compliance.
Group 3-8:
Remove the scuff plates at the lower corners of the aft entry doorway and aft galley doorway. If the rain gutters interfere with the Low Frequency Eddy Current Inspection (LFEC), remove them from above the aft entry doorway and aft galley doorway. At the upper and lower corners of the aft entry doorway and aft galley doorway, do an external LFEC inspection of the skin assembly and the bear strap for any crack around fasteners and do an external detailed inspection of the skin assembly for any crack. If any crack is found in the skin assembly or bear strap, install a repair in accordance with Structural Repair Manual (SRM). If no crack is found, do the repeat inspections at the intervals given in Paragraph 1.E., Compliance.
EFFECTIVITY All 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 (AD) related to this service bulletin. The AD 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 inspections and/or repair procedures given in this service bulletin.
MANPOWER Elapsed HoursTotal Task HoursAirplanes --Group 1
8.008.00Group 2
8.0016.00Group 3-8 Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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BOEING SERVICE BULLETIN 737-53A1350
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DO AN EXTERNAL LFEC INSPECTION OF THE
SKIN ASSEMBLY AND THE BEAR STRAP FOR ANY CRACK AROUND FASTENERS. DO A
DETAILED INSPECTION OF THE SKIN ASSEMBLY FOR ANY CRACK. IF ANY CRACK IS FOUND, DO THE REPAIR. IF NO CRACK IS FOUND, DO REPEAT INSPECTIONS.
STA STA STA STA 1016 992.8 951 908
- S-6R
- S-8R -S-10R
BEAR STRAP
- S-14R — S-17R
- S-20R
AFT GALLEY DOORWAY SHOWN FWD
AFT ENTRY DOORWAY SIMILAR INSPECTION AREA 2399738 Original Issue: May 06, 2016 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1350 Work - See page 1 for details. 8 of 123
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1350 Original Issue: May 06, 2016 ATA System: 5331 SUBJECT: FUSELAGE - Skin - Upper and Lower Corners of Aft Doorways 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 This service bulletin is applicable to all 737-100, -200, -200C, -300, -400 and -500 airplanes, in 8 Groups. The Variable Numbers and Group Information for the applicable airplanes are given 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 airplanes, line numbers 1-291.-1 737-200 airplanes without aft entry doors.-2 737-200/-200C airplanes with aft entry doors with airstairs.-3 737-200/-200C airplanes with aft entry doors that do not have airstairs.-4 737-300/-400/-500 airplanes, line numbers 1001-1072 and 1074-2552.-5 737-300 airplane, line number 1073.-6 737-300/-400/-500 airplanes, line numbers 2553-2565.-7 737-300/-400/-500 airplanes, line numbers 2566-3132.-8 Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 06, 2016 737-53A1350 9 of 123
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 4PG584 - PG586 1PG621 - PG630 1PG651 - PG652 1PG701 - PG705 4PH001 4PH011 - PH013 4PH021 - PH024 1PH701 - PH715 1PH731 - PH732 1PH741 - PH742 4PH743 1PJ001 - PJ002 4PJ003 - PJ009 1PJ031 - PJ032 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1PJ071 - PJ072 1PJ101 - PJ104 4PJ105 - PJ119 2PJ201 - PJ219 5PJ301 - PJ302 5PJ551 7PJ552 8PJ553 - PJ561 8PJ601 - PJ615 8PJ811 8PJ816 - PJ817 4PK026 - PK029 4PK041 - PK053 4PK061 - PK067 3PK068 - PK070 4PK081 - PK082 4PK091 - PK099 4PK101 - PK103 4PK111 - PK120 4PK141 - PK146 4PK201 - PK204 4PK211 - PK223 4PK231 - PK241 4PK251 - PK258 4PK271 - PK274 4PK281 - PK289 4PK291 4PK301 - PK318 4PK341 4PK351 - PK361 4PK391 4PK431 - PK433 4PK451 - PK452 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 4PK461 - PK469 4PK495 4PK501 - PK504 4PK511 - PK515 3PK519 4PK521 - PK528 4PK541 - PK565 4PK581 4PK591 - PK599 4PK601 - PK617 4PK621 - PK637 4PK641 - PK642 4PK661 - PK666 4PK671 - PK681 4PK691 - PK697 4PK711 - PK716 4PK731 - PK765 4PK771 - PK779 4PK801 - PK804 4PK819 - PK827 4PK830 4PK861 - PK863 4PK871 - PK874 4PK881 - PK884 4PK901 - PK938 4PK971 - PK974 4PL001 - PL028 4PL061 4PL081 4PL101 - PL113 4PL151 4PL171 - PL172 4PL201 - PL203 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: May 06, 2016 737-53A1350 12 of 123 BOEING SERVICE BULLETIN 737-53A1350