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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-57A1308 Original Issue: August 21, 2009 Revision 1: October 01, 2009 ATA System: 5720 SUBJECT: WINGS - Outer Wing - Skins - Lower Wing Skin at Fuel Tank Access Door Cutout Keyway - Inspection and Change Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2009 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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 the Boeing livery 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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 1 of 44
3.0
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 2 of 44 BOEING SERVICE BULLETIN 737-57A1308
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Table of Contents
Revision Transmittal Sheet5
Summary7
1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 3 F. Approval ............................................... 1 4 G. Manpower .............................................. 1 4 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 5 J. References .............................................. 1 5
1. Existing Data .......................................... 1 5
2. Data supplied with this Service Bulletin ............................ 1 5
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 6
2. MATERIAL INFORMATION ........................................ 1 7 A. Material - Price and Availability ................................... 1 7 B. Industry Support Information .................................... 1 7 C. Parts Necessary For Each Airplane ................................. 1 7
1. Kits/Parts ............................................ 1 7
2. Parts and Materials Supplied by the Operator ........................ 1 7
3. Parts Modified and Reidentified ................................ 1 7
4. Parts Removed and Not Replaced .............................. 1 7 D. Parts Necessary to Change Spares ................................. 1 7 E. Special Tooling - Price and Availability ............................... 1 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 8
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 1 9 A. GENERAL INFORMATION ..................................... 1 9 B. WORK INSTRUCTIONS ....................................... 1 9 FIGURE 1: LEFT WING - ACCESS DOOR CUTOUT - INSPECTION FOR KEYWAY ......... 2 1 FIGURE 2: RIGHT WING - ACCESS DOOR CUTOUT - INSPECTION FOR KEYWAY ........ 2 4 FIGURE 3: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION ......... 2 7 FIGURE 4: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - HFEC INSPECTION ........ 3 0 FIGURE 5: LEFT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE . . . 33 FIGURE 6: RIGHT WING - ACCESS DOOR CUTOUT KEYWAY - KEYWAY PROFILE CHANGE . . 36 FIGURE 7: LEFT WING - FUEL TANK ACCESS DOOR CUTOUT KEYWAY REPAIR ......... 3 9 FIGURE 8: RIGHT WING - FUEL TANK ACCESS DOOR CUTOUT KEYWAY REPAIR ........ 4 2
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 3 of 44 BOEING SERVICE BULLETIN 737-57A1308
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BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 4 of 44 BOEING SERVICE BULLETIN 737-57A1308
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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-57A1308Original Issue: August 21, 2009 Revision 1: October 01, 2009 ATA System: 5720 SUBJECT: WINGS - Outer Wing - Skins - Lower Wing Skin at Fuel Tank Access Door Cutout Keyway - Inspection and Change This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.
Airplane variable numbers YH301, YH302 and YH303 are added to the effectivity of this service bulletin.
REASON FOR REVISION This revision is sent to complete the approval process. The original issue was inadvertently released without completion of the full approval process.
These sections are changed:
1. In the Compliance table, the words "after the initial release date" are changed to "after the revision 1 date", in two places.
2. Airplane variable numbers YH301, YH302 and YH303 are added to the effectivity of this service bulletin.
The data given in Information Notice 737-57-1308 IN 01 is included in this revision.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
REVISION HISTORY August 21, 2009Original Issue:
October 01, 2009Revision 1:
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Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 5 of 44
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 6 of 44 BOEING SERVICE BULLETIN 737-57A1308
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-57A1308Original Issue: August 21, 2009 Revision 1: October 01, 2009 ATA System: 5720 SUBJECT: WINGS - Outer Wing - Skins - Lower Wing Skin at Fuel Tank Access Door Cutout Keyway - Inspection and Change
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 The inspection and change in this service bulletin will detect and help prevent cracks in the lower wing skins.
Cracks in the lower wing skin, if left undetected could result in the catastrophic structural failure of the wings.
Three operators have reported finding seven cracks, ranging from 0.02 to 0.380 inches in length, emanating from the keyway of the fuel tank access hole on the wing lower skin between wing rib numbers 8 and 9 on Boeing 777-200LR and 777-300ER airplanes. The fuel tank access door at this location has a fuel measuring stick installed and the keyway is used to ensure that the fuel measuring stick is oriented correctly when the fuel tank access door is installed. The crack is believed to be the result of fatigue due to the position of the keyway. The lower wing skins on the Boeing 737-900ER Series Airplanes have fuel tank access holes with the same configuration as that of the affected fuel tank access holes on the 777-300ER airplanes. The affected fuel tank access holes on the 737-900ER are located between ribs 4 and 5, between Wing Station (WSTA) 180 and WSTA 204.25. These fuel tank access holes are for fuel tank access doors 531BB and 631BB. Although cracks have not yet been reported on any 737-900ER airplane, damage tolerance analysis shows crack potential for the 737-900ER lower wing skins at the noted locations. If a crack initiates, and grows unchecked, it could result in the loss of the lower wing skin load path. The loss of the lower wing skin load path could result in the catastrophic structural failure of the wing.
Inspection of the keyway will detect cracks in the keyway before the cracks can grow to the point the lower wing skin load path is lost. Changing the profile of the keyway will improve the fatigue characteristics of the keyway which will help prevent cracks in the future. The change in the profile of the keyway can also be used to repair cracks up to 0.030 inch in length.
If any crack is found that is greater than 0.30 inch in length, skin panel replacement may be required. Skin panel replacement would require significant manpower and extended downtime.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 7 of 44
The change given in this Service Bulletin is incorporated in production on 737-900ER series airplanes from line number 2990 onwards.
Boeing Service Related Problem (SRP) 777-SRP-57-0222 is related to this service bulletin.
ACTION Drain and purge the center fuel tank. Remove the fuel tank access doors 531BB and 631BB between wing rib numbers 4 and 5, between WSTA 180 and WSTA 204.25. Inspect the fuel tank access door cutouts for a keyway.
If a keyway does not exist then no more work is necessary. If a keyway does exist then do a one time High Frequency Eddy Current (HFEC) inspection of the keyway in the fuel tank access door cutout for cracks. If no crack is found or any crack found is 0.030 inch in length or less, change the profile of the keyway to obtain a larger radius and remove the crack, if present. If any crack greater than 0.030 inch is found, contact Boeing for repair instructions and do the repair. Install the fuel tank access doors 531BB and 631BB.
EFFECTIVITY 737-900ER Airplanes. Refer to Paragraph 1.A., Effectivity 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.
See Paragraph 1.E., Compliance for compliance information.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of May 1, 2008. Please refer to Paragraph
2.B., Industry Support Information.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 8 of 44 BOEING SERVICE BULLETIN 737-57A1308
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BOEING SERVICE BULLETIN 737-57A1308
ALERT ALERT RIB 5 RIB 4 (MAIN TANK WALL) INBD CENTER
FUEL TANK
ACCESS DOOR
CUTOUT KEYWAY
LEFT WING SHOWN LEFT MAIN
RIGHT WING OPPOSITE FUEL TANK
VIEW LOOKING UP
CLAMP RING
DO A HIGH FREQUENCY EDDY CURRENT
INSPECTION OF THE ACCESS DOOR CUTOUT KEYWAY FOR CRACKS. •
CHANGE PROFILE OF THE ACCESS DOOR
CUTOUT KEYWAY TO OBTAIN LARGER RADIUS AND REMOVE CRACKS IF PRESENT.
Original Issue: August 21, 2009 Revision 1: October 01, 2009 737-57A1308
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 44
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 10 of 44 BOEING SERVICE BULLETIN 737-57A1308
ALERTALERT
BLANK PAGE
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-57A1308 Original Issue: August 21, 2009 Revision 1: October 01, 2009 ATA System: 5720 SUBJECT: WINGS - Outer Wing - Skins - Lower Wing Skin at Fuel Tank Access Door Cutout Keyway - Inspection and Change
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 Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 737-900ER Series Airplanes with a keyway in the wing lower skin at fuel tank access doors 531BB and 631BB.
-1 Airplane Models:
737-900ER GroupVariable Number 1YH001 - YH012 1YH031 - YH039 1YH051 - YH055 1YH101 - YH126 1YH201 - YH202
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Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 11 of 44
GroupVariable Number 1YH206 - YH207 1YH301 - YH303 1YH321 - YH322
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason The inspection and change in this service bulletin will detect and help prevent cracks in the lower wing skins. Cracks in the lower wing skin, if left undetected could result in the catastrophic structural failure of the wings.
Three operators have reported finding seven cracks, ranging from 0.02 to 0.380 inches in length, emanating from the keyway of the fuel tank access hole on the wing lower skin between wing rib numbers 8 and 9 on Boeing 777-200LR and 777-300ER airplanes. The fuel tank access door at this location has a fuel measuring stick installed and the keyway is used to ensure that the fuel measuring stick is oriented correctly when the fuel tank access door is installed. The crack is believed to be the result of fatigue due to the position of the keyway. The lower wing skins on the Boeing 737-900ER Series Airplanes have fuel tank access holes with the same configuration as that of the affected fuel tank access holes on the 777-300ER airplanes. The affected fuel tank access holes on the 737-900ER are located between ribs 4 and 5, between Wing Station (WSTA) 180 and WSTA 204.25. These fuel tank access holes are for fuel tank access doors 531BB and 631BB. Although cracks have not yet been reported on any 737-900ER airplane, damage tolerance analysis shows crack potential for the 737-900ER lower wing skins at the noted locations. If a crack initiates, and grows unchecked, it could result in the loss of the lower wing skin load path. The loss of the lower wing skin load path could result in the catastrophic structural failure of the wing.
Inspection of the keyway will detect cracks in the keyway before the cracks can grow to the point the lower wing skin load path is lost. Changing the profile of the keyway will improve the fatigue characteristics of the keyway which will help prevent cracks in the future. The change in the profile of the keyway can also be used to repair cracks up to 0.030 inch in length.
If any crack is found that is greater than 0.30 inch in length, skin panel replacement may be required.
Skin panel replacement would require significant manpower and extended downtime.
The change given in this Service Bulletin is incorporated in production on 737-900ER series airplanes from line number 2990 onwards.
Boeing Service Related Problem (SRP) 777-SRP-57-0222 is related to this service bulletin.
Revision 1 is sent to complete the approval process. The original issue was inadvertently released without completion of the full approval process.
BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: August 21, 2009 737-57A1308Revision 1: October 01, 2009 12 of 44 BOEING SERVICE BULLETIN 737-57A1308