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February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 77
Commercial Airplane Group 737 Service Bulletin Number: 737-78-1069 Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831 SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification
BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2002 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.
BLANK PAGE February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 77 BOEING SERVICE BULLETIN 737-78-1069
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Table of Contents February 28, 2002 Revision 4 June 16, 2005 737-78-1069 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 77 BOEING SERVICE BULLETIN 737-78-1069
Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 25
3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 25 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 25
2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 33
3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 35
3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 1: THRUST REVERSER INSULATION BLANKET REMOVAL . . . . . . . . . . . . . . . . 40 FIGURE 2: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL . . . . 42 FIGURE 3: GROUP 1 AND GROUP 2 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT . 46 FIGURE 4: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REMOVAL . . . . . . . . . . . 50 FIGURE 5: GROUP 3 - LEFT AND RIGHT THRUST REVERSER UPPER AND LOWER INSULATION BLANKET SUPPORT BRACKET (FORWARD EDGE) REPLACEMENT . . . . . . . . 54 FIGURE 6: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET FASTENER GROMMET ADDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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FIGURE 7: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SKIN GROMMET ADDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FIGURE 8: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET SUPPORT ATTACHMENTS - STUD BOLT AND CLICK-BOND ADDITION . . . . . . . . . . . . . 67 FIGURE 9: LEFT AND RIGHT THRUST REVERSER INSULATION BLANKET INSTALLATION . . . 71 FIGURE 10: THRUST REVERSER INSULATION BLANKET FASTENER AND SKIN GROMMET DRILL AND DRILL GUIDE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 APPENDIX A: SKIN GROMMET INSTALLATION - TOOL SET-UP . . . . . . . . . . . . . . . . . . 75 APPENDIX B: ADHESIVE BONDED STUD - CLICK BOND FASTENER INSTALLATION . . . . . . 76
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Commercial Airplane Group 737 Service Bulletin Number: 737-78-1069 Revision Transmittal Sheet Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831 SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed as shown in Revision 3 of this service bulletin.
REASON FOR REVISION Revision 4 is sent to move airplane YA531 from Group 2 to Group 3 and to add three optional parting agents.
Airplane YA531 is moved from Group 2 to Group 3 in Paragraph 1.A., Effectivity, and three optional parting agents are added to Paragraph 2.C.2., Parts and Materials Supplied by the Operator and to Figure 9, Step 3.
The data given in Information Notice 737-78-1069 IN 03 and 737-78-1069 IN 04 is included in this revision.
Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes 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 Original Release: February 28, 2002 Revision 1: June 13, 2002 Revision 2: February 6, 2003 Revision 3: August 5, 2004 Revision 4: June 16, 2005
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Commercial Airplane Group 737 Service Bulletin Number: 737-78-1069 Summary Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831 SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification
CONCURRENT REQUIREMENTS Operators of Group 1 airplanes cannot make the changes given in this service bulletin unless service bulletin 737-78-1063 has been incorporated. Group 2 and Group 3 airplanes received the equivalent change to that given in 737-78-1063 before delivery.
BACKGROUND Many operators have reported damaged insulation blankets on the engine thrust reverser halves. Some operators have also reported wear damage and pitting on the forward end of the engine thrust links. Boeing found that external air pressure can get under the insulation blankets and expand the blankets toward the engine. This can result in wear damage to the insulation blankets, engine thrust links and other engine components.
The change given in this bulletin corrects the chafe condition between the insulation blankets and the engine components. It eliminates worn insulation blankets and worn engine components.
As part of a service bulletin validation program, this change was completed on one engine of airplane YD050 by Service Bulletin 737-78-1069 Validation Copy 2 before the initial release of this service bulletin. The change completed on airplane YD050 by Service Bulletin 737-78-1069 Validation Copy 2 is equivalent to the initial release of this service bulletin. Airplane YD050 has the configuration of a Group 3 airplane.
ACTION (PRR 38394) This change installs more supports on the inner wall of the thrust reverser for the attachment of the insulation blankets. New brackets are installed to attach the forward edge of the upper and lower insulation blankets.
More attachment grommets are added to the blankets. The blankets are sealed at the forward edge of the fan duct inner walls to prevent the flow of air under the blankets.
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EFFECTIVITY 737-600, -700, -700C, -800, -900 Airplanes. Refer to service bulletin Paragraph 1.A.1. for effectivity.
COMPLIANCE No compliance time is given.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of October 7, 1999. Please refer to Paragraph 2.B., Industry Support Information.
MANPOWER
MATERIAL INFORMATION Boeing Supplied Kits/Parts Refer to Paragraph 2.A., Material - Price and Availability.
Airplane Line Positions Group 1 2 thru 20, 22 thru 40 and 172 Group 2 1, 21, 41 thru 171, 173 thru 346 Group 3 347 thru 700 Total Elapsed Time Airplanes Man-Hours (Hours) Remove and Install Thrust Reversers 30.0 8.0 Part I - Changes 54.0 13.5 Part II - Changes 56.0 14.0
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TO FAN DUCT WALLS
ADD MORE BLANKET SUPPORTS
INSULATION BLANKETS AND
REWORK THE UPPER AND LOWER
LEFT SIDE SHOWN, RIGHT SIDE SIMILAR FWD
REVERSER THRUST V39526
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Commercial Airplane Group 737 Service Bulletin Number: 737-78-1069 Date: February 28, 2002 Revision 4 June 16, 2005 ATA System: 7831 SUBJECT: EXHAUST - Thrust Reverser - Insulation Blanket Modification
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 38394 for data about this change.
Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
Airplane models:
737-600 737-700 737-700C 737-800 737-900
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
AIR ALGERIE (ALG) 3 YD101–YD104
GROUP CONFIGURATION DESCRIPTION 1 - Airplanes use Kit Numbers 012A0020-1, 012A0020-5 and 012A0020-6. Boeing Service Bulletin 737-78-1063 must be done before or at the same time as this service bulletin.
2 - Airplanes use Kit Numbers 012A0020-1, 012A0020-5 and 012A0020-6. No concurrent requirements.
3 - Airplanes use Kit Number 012A0020-2. No concurrent requirements.
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AIR BERLIN (BER) 1Y C 0 5 1 2 YC052–YC058 YC701 YC703 3 YC059–YC064
AIR CHINA (BEJ) 3 YA681–YA682 YC944–YC947 YC981–YC983
AIR CHINA CHONGQING BRANCH (CHO) 2Y C 9 4 1 3 YC942–YC943
AIR EUROPA (ARE) 2 YC761–YC763 3 YC764–YC770
AIR HORIZONS (AHZ) 2Y C 7 0 4 3Y C 7 0 7
AIR MAURITANIE (MAR) 1 YA302
AIR NATIONAL GUARD (USK) 3Y G 0 6 7 Y G 0 6 9
AIR PACIFIC (APC) 2 YA291 YC931–YC932
AIR SAHARA (SAQ) 2 YA253–YA254 YA731 YG001 3 YC901–YC902
AIR SHAMROCK (SHI) 2Y G 0 1 6
ALASKA AIRLINES (ASA) 2 YA841 3 YA842–YA852 YD501–YD502
ALOHA AIRLINES (ALO) 3 YA608 YA610 YA732–YA733
AMERICAN AIRLINES (AAL) 2 YC801–YC816 3 YC817–YC848
AMIRI FLIGHT (ABD) 2Y G 0 2 3 3Y G 0 2 6
ARAMCO ASSOCIATED COMPANY (RAS) 3 YB151–YB152