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December 11, 2003 737-52-1149 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 80
Commercial Airplane Group 737
SPECIAL ATTENTION Service Bulletin Number: 737-52-1149 Date: December 11, 2003 ATA System: 5231 AXC SUBJECT: DOORS - Forward Cargo Door - Number 4 Cross Beam Inspection, Repair and Preventative Modification
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2003 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue 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.
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December 11, 2003 737-52-1149 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 80
Commercial Airplane Group 737
SPECIAL ATTENTION Service Bulletin Number: 737-52-1149 Summary Date: December 11, 2003 ATA System: 5231 AXC SUBJECT: DOORS - Forward Cargo Door - Number 4 Cross Beam Inspection, Repair and Preventative Modification BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND Four operators have reported cracks in the forward cargo door. The cracks occurred in the web and in the T-chord of the number 4 cross beam. Cracks in the cross beam web were up to 1 inch long. Cracks in the T-chord were up to 1.3 inches long. Airplanes had accumulated between 41,000 and 79,000 flight cycles.
A crack in the number 4 cross beam combined with a crack in the number 5 cross beam on the forward cargo door may result in a rapid loss of cabin pressure. If cracks occur in the number 5 cross beam it will increase the load in the number 4 cross beam and could cause it to crack prematurely. Cracking in the number 5 cross beam is covered in the subject of Alert Service Bulletin 737-52A1100.
Boeing Structural Item Interim Advisory (SIIA) 737-287 is related to this service bulletin.
Boeing Service Related Problem (SRP) 737-SRP-52-0070 is related to this service bulletin.
As a part of a service bulletin validation program, this change was completed on airplane PW317 by Service Bulletin 737-52-1149 Validation Copy 01 before the initial release of this service bulletin. The change completed on airplane PW317 by Service Bulletin 737-52-1149 Validation Copy 01 is equivalent to the initial release of this service bulletin. Airplane PW317 has the configuration of a Group 1 airplane.
ACTION (PRR 35005-248RS) This Service Bulletin is divided into 2 groups. Group 1 airplanes have forward cargo doors with a bonded inner skin and Group 2 airplanes have forward cargo doors with a chemically milled inner skin.
On the forward cargo door do a visual inspection and High Frequency Eddy Current (HFEC) inspection for cracks in the number 4 cross beam web, the T-chord flange and the T-chord root radius. If no cracks are found install the cross beam preventative modification or repeat the inspection at the given intervals. If cracks are found in the cross beam web or the T-chord, install the cross beam web and T-chord repair.
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It is recommended that Boeing service bulletin 737-52A1100 and this service bulletin be incorporated concurrently. Since both service bulletins remove fasteners in the door frame and inner skin, concurrent incorporation will minimize rework to these parts. If service bulletin 737-52A1100 is worked concurrently, partially remove inner skin to gain access instead of cutting access holes as specified in this service bulletin.
Reassemble the inner skin with production fasteners or approved substitutes. These fasteners are not included in the supplied kit.
Note that service bulletin 737-52A1100 is mandated by Airworthiness Directive 2000-07-06. If incorporation of this service bulletin results in changes that affect incorporation of service bulletin 737-52A1100, it may be necessary to seek alternate means of compliance (AMOC) for the Airworthiness Directive.
EFFECTIVITY All 737-100/-200/-200C/-300/-400/-500 series airplanes.
COMPLIANCE For compliance times refer to the table in paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.
MANPOWER
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Airplanes Total Task Hours Elapsed Hours Group 1 72 36 Group 2 72 36
December 11, 2003 737-52-1149 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 80 BOEING SERVICE BULLETIN 737-52-1149
OUTER
SKINTYPICALCRACK
BEAM WEBT-CHORD FRAME SEAL
FITTING STOP WEB
INNER SKIN
CRACK IN WEB AND OUTER CHORD AT AFT END OF BEAM SHOWN,
CRACK IN WEB AT FORWARD END OF BEAM SIMILAR A-A STA STA 540 360 STA 460 FWD FWD FWD
HAVE A CHEMICALLY MILLED INNER SKIN WITH A BONDED INNER SKIN AND GROUP 2 AIRPLANES GROUP 1 AIRPLANES HAVE A FORWARD CARGO DOOR
CROSS BEAM NUMBER 4
TYPICAL CRACKS
T-CHORD REPEAT INSPECTIONS.
THE PREVENTATIVE MODIFICATION OR FOUND. IF NO CRACKS ARE FOUND DO
FOR CRACKS, REPAIR IF CRACKS ARE INSPECT THE NUMBER 4 CROSS BEAM A A
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December 11, 2003 737-52-1149 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 80
Commercial Airplane Group 737
SPECIAL ATTENTION Service Bulletin Number: 737-52-1149 Date: December 11, 2003 ATA System: 5231 AXC SUBJECT: DOORS - Forward Cargo Door - Number 4 Cross Beam Inspection, Repair and Preventative Modification BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 35005-248RS for data about this change.
Airplane models:
737-100 737-200 737-200C 737-300 737-400 737-500
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
ADC AIRLINES (ADN) 1 PJ117–PJ119 AEGEAN AIRLINES S.A. (CRM) 1 PM392 PP929 PS608 PW002 PW053 PW157 PW261 PW564
AER LINGUS (ARL) 1 PT161–PT168 PW594–PW596
AERGO CAPITAL LIMITED (CLJ) 1P K 7 7 2
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AERIS (AEY) 1 PM381 PP838 PQ307 2 PQ345–PQ346
AERO CONTINENTE (COH) 1 PA002 PG021 PG041 PG074 PG218–PG219 PG224 PG305 PG308 PG310–PG311 PG574 PJ002–PJ003 PJ102 PL758
AERO CONTROLS (AEO) 1P G 3 1 2
AEROFLOT (ARO) 2 PW441–PW450
AEROLINEAS ARGENTINAS (ARG) 1 PG584–PG585 PH705–PH708 PH741–PH743 PK102–PK103 PK735–PK737 PK739–PK740 PK747 PK750–PK751 PK755 PK759–PK765 PN112 PY007
AEROMAR AIRLINES (AOO) 1 PM103
AEROSERVICE (SRI) 1 PL742–PL743
AEROSUCRE (SUS) 1 PY201 PY341
AEROSVIT (UKA) 1 PK564 PQ284 PT614–PT616 PW592
AIGLE AZUR (AZU) 1 PK215 PL504 PM554 PP947 PW010 PW046
AIR ALGERIE (ALG) 1 PK361 PK633–PK634 PL717–PL725 PY051 PY053
AIR ATLAS EXPRESS (YCZ) 1P W 0 2 1
AIR AUSTRAL (AUX) 1P T 2 1 5 2 PR096 PS621
AIR BERLIN (BER) 2 PJ811 PW524 PW528–PW530
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AIR CANADA (ACN) 1 PK358 PK671 PK674–PK675 PK677–PK681 PK822 PK881 PK884 PL401–PL417 PL767–PL770 PM141–PM142 PY152–PY154 PY422 PY441
AIR CHINA (BEJ) 1 PP521–PP522 PQ361–PQ364 PQ367 2 PQ368–PQ369 PQ371–PQ373 PQ988 PQ990
AIR CHINA INNER MONGOLIAN (IML) 1 PQ365–PQ366 PS614–PS616 2P Q 3 7 0 P S 6 1 7
AIR EUROPA (ARE) 1 PS657 PW065–PW066 PW265 PW517 2 PR002 PW266
AIR FRANCE (AFA) 1 PP902 PP910–PP912 PS604 PT214 PT501–PT509 2 PQ991 PT169–PT170 PT303–PT306 PT309 PT510–PT514 PU311–PU313
AIR GABON (GBN) 1 PP836 PW562 PY191
AIR GREAT WALL (GWA) 1 PM281–PM283
AIR GUINEE (GNE) 1 PN456 PY651
AIR INTER CAMEROUN (ICM) 1P Y 2 7 4
AIR KAZAKSTAN (KAZ) 1 PG629 PK284 PK563 PM252
AIR MADAGASCAR (MAD) 1 PG375 PL793 PP852 2P Q 2 9 9
AIR MALAWI (AML) 1P S 6 0 2
AIR MALTA (MLT) 1 PL624–PL625 PQ302 PQ306 2 PQ791–PQ793 PS873–PS874
AIR MEDITERRANEE (AMV) 1 PG028–PG029 PG036 PT023 PY101 PY103 PY301
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AIR NAMIBIA (NAM) 1 PK355 PN492
AIR NAURU (NAU) 2P W 5 5 6
AIR NEW ZEALAND (ANZ) 1 PS651 2 PQ997 PR009 PR014 PR041 PR045 PR062–PR066 PR077–PR080 PR101 PS866–PS868
AIR NIPPON (ANK) 1P T 0 5 3 P W 0 2 6 2 PJ817 PT060 PT063–PT064 PT126 PT128–PT131 PT871–PT886
AIR NORTH YUKON'S AIRLINE (AND) 1 PK596 PK599
AIR ONE (ADH) 1 PK432 PK933 PK938 PM410–PM411 PQ228–PQ229 PV232–PV234 PV236–PV237 PW041 PW043 PW052 PW054 2 PQ347–PQ348 PW106 PW267 PW288 PW831 PW851
AIR PHILIPPINES (PHP) 1 PG001 PG039 PG061–PG062 PG066 PK099 PK541–PK542 PM394–PM395
AIR PLUS COMET (PLD) 1 PP904
AIR POLONIA (APL) 2P W 2 6 2 P W 2 6 4
AIR SAHARA (SAQ) 1 PL452 PW061 PW064 PW114
AIR SENEGAL INTERNATIONAL (SNG) 1 PK274
AIR SLOVAKIA (SLO) 1 PK546 PK936–PK937
AIR TANZANIA (TNZ) 1 PP926 PY611
AIR VANUATU (VAN) 2P Q 4 5 4
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AIR ZIMBABWE (ZMB) 1 PN431–PN433
AIRASIA (ASW) 1 PM397–PM398 PP509 PP517 PP848 PP920 2P Q 4 4 8
AIRCALIN (NCI) 1P P 9 1 8
AIRFAST INDONESIA (PTF) 1 PK562 PN481 PY343
AIRTRAN (CQT) 1P K 3 0 6 P K 6 9 7
AIRWORK NZ (ANX) 1P Y 7 4 1
AIRZENA (GEI) 1P T 6 1 1
ALASKA AIRLINES (ASA) 1 PJ301–PJ302 PW116 PW231–PW238 PY112 PY134–PY135 PY270 PY461–PY463 PY593–PY594 2 PJ601–PJ615 PW239–PW252
ALOHA AIRLINES (ALO) 1 PK286 PK905 PK926 PK934–PK935 PL626 PM251 PM253 PN085 PN473 PN493 PY231 PY242 PY451 PY592 PY595 PY721
ALTER FINANCE (AFW) 1P K 2 8 2 P K 3 5 9
AMC AVIATION (AMF) 1P K 2 5 4
AMERICA WEST AIRLINES (AMW) 1 PL081 PL172 PL551–PL553 PL555–PL557 PL559–PL562 PP022 PP029 PP183–PP187 PP189 PP194–PP195 PP197–PP199 PP383 PP472 PP474–PP475 PP831 PP833–PP834 PP846 PP891 PP893 PP895 PP898–PP899 PP901 PP931–PP934 PP936 PS666–PS669 2 PR067
AMERICAN FALCON AIR (FAK) 1 PK464 PL026
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AMERISTAR AIR CARGO (CGG) 1 PY345–PY346
AMTEC CORPORATION (CEF) 1 PK549
ANSETT AUSTRALIA (ANS) 1 PP908–PP909 PP914 PQ026 PQ028 PQ031 PQ036–PQ037
ANSETT WORLDWIDE AVIATION (AWW) 1 PP948
ANTINEA AIRLINES (NTI) 1 PY006
ARAL (RII) 1P W 0 3 1
ASIANA AIRLINES (AAR) 1 PV201–PV202 PW005 PW008–PW009 PW018–PW020 PW025 2 PT851–PT853 PV204–PV206 PV208 PV226–PV229 PW274 PW278 PW283 PW286 PW289 ASTRAEUS, LTD. (AUA) 1 PP515 PP845 PP935 2P Q 9 9 4
ATA ATLANTICO TRANSPORTE AEREO (AUI) 1 PY003 PY321–PY322
AUSTRAL - CIELOS DEL SUR (ALA) 1 PN103–PN104 PN110–PN111 PN113–PN115 PN117
AVENSA (AVN) 1 PK042
AVIACSA AEROEXO (AEJ) 1 PK216–PK220 PK289 PK598 PK625–PK626 PM101–PM102 PM107 PM115–PM117 PM181 PN454