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Commercial Airplanes 737 Requirements Bulletin ALERT Number: 737-53A1385 RB Original Issue: August 16, 2019 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Missing Shim at STA 727 Inner Chord to Stringer S-18A Web - Inspection 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:
Copyright © 2019 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Unpublished Work.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.
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Table of Contents
1 . E F F E C T I V I T Y5
A. Airplanes5
B . S p a r e s A f f e c t e d6
2. CONCURRENT REQUIREMENTS6
3 . C O M P L I A N C E6
4. APPROVAL ................................................ 1 0
5. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 1 A. General Information ......................................... 1 1 B. Work Instructions ........................................... 1 2 FIGURE 1: GENERAL VISUAL INSPECTION AT STA 727 FRAME INNER CHORD AT S-18A LEFT SIDE .................................................. 1 7 FIGURE 2: GENERAL VISUAL INSPECTION AT STA 727 FRAME INNER CHORD AT S-18A RIGHT SIDE .................................................. 2 1 FIGURE 3: DETAILED INSPECTION FOR UNSHIMMED GAP AT STA 727 FRAME INNER CHORD AT S - 1 8 A L E F T S I D E....................................... 2 5 FIGURE 4: DETAILED INSPECTION FOR UNSHIMMED GAP AT STA 727 FRAME INNER CHORD AT S - 1 8 A R I G H T S I D E...................................... 3 0 FIGURE 5: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTIONS OF THE STA 727 FRAME I N N E R C H O R D A T S - 1 8 A L E F T S I D E ............................ 3 5 FIGURE 6: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTIONS OF THE STA 727 FRAME I N N E R C H O R D A T S - 1 8 A R I G H T S I D E ........................... 3 9 FIGURE 7: SHIM INSTALLATION FOR THE STA 727 FRAME INNER CHORD AT S-18A LEFT SIDE . 43 FIGURE 8: SHIM INSTALLATION FOR THE STA 727 FRAME INNER CHORD AT S-18A RIGHT SIDE .................................................. 4 7 FIGURE 9: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE S TA 727 FRAME INNER C H O R D A T S - 1 8 A L E F T S I D E................................ 5 1 FIGURE 10: HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION OF THE STA 727 FRAME INNER C H O R D A T S - 1 8 A R I G H T S I D E ................................ 5 4 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 737 Requirements Bulletin ALERT Number: 737-53A1385 RB Original Issue: August 16, 2019 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Missing Shim at STA 727 Inner Chord to Stringer S-18A Web - Inspection
THIS DOCUMENT 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 DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING
PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1. Effectivity A. Airplanes This bulletin is applicable to 737-700, 737-800, 737-900ER Airplane(s), line number(s) 6071-6073, 6075, 6077-6103, 6105-6113, 6115-6131, 6133-6153, 6155-6159, 6161-6187, 6190-6215, 6217-6221, 6223-6229, 6231-6243, 6245-6249, 6251-6269, 6271, 6274, 6276-6289, 6291-6292, 6294-6299, 6301, 6303, 6305-6307, 6309-6314, 6316-6318, 6320-6322, 6324-6325, 6327, 6329 in 1 Group(s). Where the effectivity is presented with hyphens between line numbers, the airplane applicability means "through" and "inclusive", e.g. line numbers 1-9 means line numbers 1 through 9 inclusive.
DESCRIPTIONCONFIGURATIONGROUP 737-700, 737-800 and 737-900ER Airplanes.-1 Airplane Models:
737-700, 737-800, 737-900ER GroupVariable Number 1YH684 1YH866 - YH875 1YN758 1YQ363 - YQ365 GroupVariable Number 1YR050 1YR210 - YR211 1YS370 1YS378 GroupVariable Number 1YS464 - YS465 1YS517 1YS897 1YS945 - YS947 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1YS953 - YS955 1YS973 - YS974 1YT120 - YT121 1YT133 1YT184 - YT185 1YT290 - YT299 1YT347 - YT354 1YT371 1YT477 1YT565 1YT575 - YT576 1YT781 1YT938 - YT960 1YU055 - YU060 1YU215 1YU302 - YU306 1YV004 1YV012 1YV021 - YV023 GroupVariable Number 1YV030 - YV031 1YV052 1YV098 1YV129 - YV138 1YV251 1YV256 1YV307 - YV312 1YV363 1YV386 - YV388 1YV391 - YV393 1YV411 1YV441 1YV503 1YV579 1YV657 - YV659 1YV730 - YV731 1YV751 - YV754 1YV784 1YV804 - YV807 GroupVariable Number 1YV904 - YV907 1YV973 - YV976 1YW050 - YW079 1YW081 - YW083 1YW234 - YW236 1YW245 1YW267 - YW271 1YW273 - YW274 1YW283 1YW357 - YW358 1YW372 - YW384 1YW451 - YW452 1YW471 - YW472 1YW891 - YW893 1YW907 1YW916 - YW918 1YW971 - YW973 -- -- B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 737-53A1385 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements Bulletin 737-53A1385 RB mandatory.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Accomplish the required action(s), based on the applicable condition(s) in Table(s) 1 and 2, in accordance with the Accomplishment Instructions.
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Table 1: Inspections of the STA 727 Frame Inner Chord at S-18A: Left Side Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 7,000 flight cycles after the original issue date of the Requirements Bulletin 737- 53A1385 RB.
Before 22,500 total flight cycles.
Do a General Visual Inspection for any repair of STA 727 frame inner chord at S-18A.
ALL AIRPLANES -Before further flight.Contact The Boeing Company for alternative inspection(s) to Requirements Bulletin 737- 53A1385 RB, do the alternative inspection(s), and do applicable on-condition action(s).
CONDITION 1:
ANY REPAIR FOUND -Before further flight.Do a Detailed Inspection of the STA 727 frame inner chord at S-18A for any unshimmed gap.
CONDITION 2:
NO REPAIR FOUND -Before further flight.Do the High Frequency Eddy Current (HFEC) inspections of the STA 727 frame inner chord at S- 18A for any crack.
CONDITION 2.1:
ANY UNSHIMMED GAP FOUND -Before further flight.Contact The Boeing Company for repair instructions and do the repair.
CONDITION 2.1.1:
ANY CRACK FOUND -Before further flight.CONDITION 2.1.2 (AC- TION 1):
CONDITION 2.1.2:
NO CRACK FOUND Do the shim installation between the STA 727 frame inner chord and S- 18A.
-Within 30,000 flight cycles after the shim installation.
CONDITION 2.1.2 (AC- TION 2):
Do a High Frequency Eddy Current (HFEC) inspection of the STA 727 frame inner chord at S-18A for any crack. (a) Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Table 1: Inspections of the STA 727 Frame Inner Chord at S-18A: Left Side Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Contact The Boeing Company for repair instructions and do the repair.
CONDITION 2.1.2.1:
ANY CRACK FOUND 30,000 flight cycles-Repeat the High Frequency Eddy Current (HFEC) inspection of the STA 727 frame inner chord at S- 18A for any crack. (a) CONDITION 2.1.2.2:
NO CRACK FOUND --No further action is required.
CONDITION 2.2: NO UN-
SHIMMED GAP FOUND
(a) It is not required to do the High Frequency Eddy Current (HFEC) inspections of the STA 727 frame inner chord at S-18A in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 737-53A1385 RB and installed after the original issue date of Requirements Bulletin 737-53A1385 RB, AND
2. The installed repair was approved by the Boeing Company Organization Designation Authorization (ODA) via a FAA Form 8100-9.
Table 2: Inspections of the STA 727 Frame Inner Chord at S-18A: Right Side Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 7,000 flight cycles after the original issue date of the Requirements Bulletin 737- 53A1385 RB.
Before 22,500 total flight cycles.
Do a General Visual Inspection for any repair of STA 727 frame inner chord at S-18A.
ALL AIRPLANES -Before further flight.Contact The Boeing Company for alternative inspection(s) to Requirements Bulletin 737- 53A1385 RB, do the alternative inspection(s), and do applicable on-condition action(s).
CONDITION 3:
ANY REPAIR FOUND -Before further flight.Do a Detailed Inspection of the STA 727 frame inner chord at S-18A for any unshimmed gap.
CONDITION 4:
NO REPAIR FOUND Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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Table 2: Inspections of the STA 727 Frame Inner Chord at S-18A: Right Side Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.Do the High Frequency Eddy Current (HFEC) inspections of the STA 727 frame inner chord at S- 18A for any crack.
CONDITION 4.1:
ANY UNSHIMMED GAP FOUND -Before further flight.Contact The Boeing Company for repair instructions and do the repair.
CONDITION 4.1.1:
ANY CRACK FOUND -Before further flight.CONDITION 4.1.2 (AC- TION 1):
CONDITION 4.1.2:
NO CRACK FOUND Do the shim installation between the STA 727 frame inner chord and S- 18A.
-Within 30,000 flight cycles after the shim installation.
CONDITION 4.1.2 (AC- TION 2):
Do a High Frequency Eddy Current (HFEC) inspection of the STA 727 frame inner chord at S-18A for any crack. (a) -Before further flight.Contact The Boeing Company for repair instructions and do the repair.
CONDITION 4.1.2.1:
ANY CRACK FOUND 30,000 flight cycles-Repeat the High Frequency Eddy Current (HFEC) inspection of the STA 727 frame inner chord at S- 18A for any crack. (a) CONDITION 4.1.2.2:
NO CRACK FOUND --No further action is required.
CONDITION 4.2: NO UN-
SHIMMED GAP FOUND
(a) It is not required to do the High Frequency Eddy Current (HFEC) inspections of the STA 727 frame inner chord at S-18A in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in Requirements Bulletin 737-53A1385 RB and installed after the original issue date of Requirements Bulletin 737-53A1385 RB, AND
2. The installed repair was approved by the Boeing Company Organization Designation Authorization (ODA) via a FAA Form 8100-9.
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4. APPROVAL This Requirements Bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this document comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This document and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected by this Requirements Bulletin, the operator is responsible for obtaining appropriate regulatory agency approval before incorporating this Requirements Bulletin.
This Requirements Bulletin is also approved for airplanes having FAA Aviation Partners Boeing (APB) Supplemental Type Certificate (STC) number ST00830SE installed (not including any areas affected by the split scimitar winglet configuration).
This Requirements Bulletin is also approved for airplanes converted into 737-800BCF under project number TS14-0042 that have incorporated Boeing drawing 800A0003 specified in the Type Certification Data Sheet A16WE.
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5. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION NOTE: 1. This is an Enhanced Required for Compliance document. There w ill be a separate Service Bulletin (SB) and a separate Requirements Bulletin (RB). If an RB is mandated by an Airworthiness Directive (AD), then all applicable requirements specified in the RB must be done. For the related SB, some locations are marked RC Start and RC End to identify the requirements that are restated from the RB. For the related SB, the areas between RC Start and RC End, including sub-steps and any figures identified between RC Start and RC End, must be done to comply with the AD.
Therefore, an Alternative Method of Compliance (AMOC) is required for any deviations to steps between RC Start and RC End, including substeps and identified figures.
For the related SB, the steps not between RC Start and RC End may be deviated from using accepted methods in accordance with the operator's maintenance or inspection program without obtaining approval of an AMOC; this is provided that the steps between RC Start and RC End, including sub-steps and identified figures, can still be done as specified, and the airplane can be put back in an airworthy condition.
Figures not required for compliance are omitted from the RB.
2. This is an Enhanced Required for Compliance document. The Boe ing processes used to create the Service Bulletin (SB) and the Requirements Bulletin (RB) ensure that the information between "RC Start" and "RC End" in the SB are identical to the information in the same sections (Compliance, Work Instructions...) of the RB which the SB refers to as the related document.
3. The compliance times for the actions in WORK INSTRUCTIONS are in Compliance.
4. Boeing Service Letter 737-SL-51-042 Damage Reporting and Repa ir Plan/Design Guidelines, is an acceptable procedure to request information from Boeing for additional structural repair instructions. The Service Letter describes what information must be provided to Boeing before a structural repair can be provided.
5. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches – Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch – Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch – Angular tolerance is plus or minus 2 degrees – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 – Torque Values:
— Values for structural fasteners are given in 737 Structural Repair Manual, Chapter 51.
— Values for airframe maintenance tasks are included in Chapter 20 of 737 Aircraft Maintenance Manual (AMM).
— Values for electrical maintenance tasks are included in Chapter 20 of Standard Wiring Practices Manual (SWPM).
— Values for engine maintenance tasks are included in Chapter 70 of 737 Aircraft Maintenance Manual (AMM).
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— Non-standard torque values for maintenance tasks are included in the applicable installation step.
6. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used.
7. If it is necessary to remove more parts for access, you can r emove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed.
8. Use the approved fastener, process and material substitutions in accordance with SRM Chapter 51.
9. A Detailed Inspection is defined as: An intensive examination of a specific item, installation or assembly to detect damage, failure or irregularity. This could include tactile assessment in which a component or assembly can be checked for tightness/security. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors and magnifying lenses may be necessary. Surface cleaning and elaborate access procedures may be required.
10. A General Visual Inspection is defined as: A visual examinat ion of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity.
This level of inspection is made from within touching distance, unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. Basic cleaning may be required to ensure appropriate visibility.
11. When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
12. If the length of any fastener specified in this service bull etin does not meet installation standards given in SRM Chapter 51, then a fastener of the same specification, or an approved substitute, with a length which meets the installation standards given in SRM Chapter 51 may be used. In addition, washers may be installed for fastener grip length in accordance with SRM Chapter 51. Refer to SOPM 20-50-01 for alternate full threaded fasteners (screws) needed for installation in this service bulletin.
B. WORK INSTRUCTIONS
1. Requirements Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
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