p03-007mm Ssid Revision 17

LOG OF REVISIONS
REVISION DATE PAGES DESCRIPTION OF REVISION APPROVAL
1 30-May-96 - Initial Release

2 26-Jun-96 1-382 -
Updated to Include Inspections and

3 18-Mar-02 1-384 Procedures based on Amendment to STC
SA2969SO
Updated To Allow the use of Visual Aides,

Borescope, Mirrors, Optical Enhancement
4 5-Nov-02 1-384
Equipment, etc… to Accomplish
Inspections in Difficult to Access Areas
Complete Revision and Re-Issue.

5 29-April-03 1-128
Task Cards and Instructions Added.
Complete Revision and Re-Issue.
6 06-May-03 1-159
Floor Beams and Detail Visual Inspection
Added.
Complete Revision and Reissue.
Inspection Intervals Changed to Reflect

737-400 Maintenance Planning Document
7 23-Mar-04 1-123
Inspection Requirements Changed to
Reflect Updated Analysis and Inspection
Procedures
05-30-10
EFFECTIVITY: ALL Page 2
Feb. 11, 2015
LOG OF REVISIONS
737-400 Inspection Program Added.

8 18-Jan-06 1-126
Inspection Requirements Changed to
Reflect Updated Analysis, Inspection
Procedures and Production Improvements
737-400 Freighter-Passenger Combi

9 31-Jul-06 1-126 Requirements Added To Inspections.
STC Numbers removed from Title Page

and Document
737-400 Freighter-Passenger Combi

Requirements Added To Inspections (IN-3)
For FS 612 Partition and Halon Support
10 1-Sept-06 1-132
Structure.
Minor Corrections Made Based On

Operator Requests For Clarification to
Inspections CD-3, LJ-2, and HINGE-1.
Unreleased Revision That Addressed 14

CFR 26 Requirements. Upon Receipt Of
11 30-Nov-10 1-175
Operator Requests, Document Revisions
Were Required.
Complete Revision and Re-Issue

Incorporating Operator Requests For
Clarification and Re-Format.
12 11-Feb-11 1-179 Revise Revision Log to Include Previous
Revision Descriptions.
Update Table 2Error! Reference source
05-30-10
Feb. 11, 2015
LOG OF REVISIONS
Complete Revision and Re-Issue

Incorporating Operator Requests For
Clarification and Re-Format.
Existing Table 2 Becomes Table 3.

Hal Horsburgh
13 15-Aug-11 1-184
11/18/2011
Include New Inspections For 11 Pallet
Configuration Included As Amendment To
STC SA2968SO For Serial Numbers
Indicated in New Table 2.
Removed aircraft serial numbers 24277,

Hal Horsburgh
14 Jan.11, 12 1-186 24279, 24988, 26284, 26288, 26292, 28271
3/21/2011
and 28334 from Table 3 on sheet 22 .
Removed aircraft serial number 23499,

Hal Horsburgh
15 April 23, 12 1-186 23500, 23741 and 24679 from Table 3 on
4/27/2012
sheet 22
05-30-10
Feb. 11, 2015
LOG OF REVISIONS
Revised SP-1 to account for two

configurations with different inspection
criteria.
Revised SP-1 and SP-2 to show only for

737-200 and -300.
Clarified EX-1, UJ-2, and HY-1 inspection

information for potential production
variations. Clarified UJ-2 for various
configurations.
Revised inspection requirments of ED-9.
Clarified aircraft configuration for CC-4 and Hal Horsburgh

16 Dec. 5, 2013 1-197
CC-5. Added CC-6 to account for aircraft 4/14/2014
737-400 Combi configuration.
Clarified CD-1 through CD-4 configurations

for installations prior to, and after, March
2001, and for installations that match
Service Bulletin 737-52-0033.
Clarified Applicablity of FRAME-1

Inspection.
Changed contact information.
Removed serial number table for 11 pallet

configuration.
05-30-10
Feb. 11, 2015
LOG OF REVISIONS
Clarified Inpsection ED-9 as applying to all

aircraft.
Clarified Inspection Requirements Of CD-1

And CD-2.
Clarified Longitudinal Floor Beam

Inspections in section 6.21.1 and IN-2.
Inspections per Boeing D6-37089 and D6-
82669 between FS540 and FS727, with the
exception of F-46. PEMCO Service
Bulletins (SB’s) 737-57-0001, 737-57-0002,
and 737-53-0026 developed to address
Boeing Airworthiness Directives in this
area.
Added Boeing D6-82669 Document

17 Feb. 11, 2015 1-198
Reference Data Throughout.
Specified GPS, TCAS, and ATC Antenna

Installations Included As Part Of This
Document.
Clarified Coupon Requirements.

Removed Table 2 (serial numbers), From
Section 6.2.4. Updated DIF forms for HY,
SP, And CC To Match Section 6.2.4
Repetitive Inspections.
Updated To Include Inspection Instructions

For 737-400 Aircraft Altered By Jetaire
Supplemental Type Certificate ST00749LA-
D, Requiring Inspections In Accordance
With 9002C0013 Per Jetaire Service
Bulletin B737-26-8016
05-30-10
Feb. 11, 2015
TABLE OF CONTENTS
LOG OF REVISIONS .............................................................................................................................................................. 2

TABLE OF CONTENTS .......................................................................................................................................................... 7
1. STRUCTURAL INSPECTION ........................................................................................................................................ 9
1.1 Purpose.................................................................................................................................................................. 9
1.2 Introduction .......................................................................................................................................................... 10
1.3 Principal Structural Elements (PSE’s) ................................................................................................................. 11
1.4 Fatigue Critical Alteration Structure (FCAS) ........................................................................................................ 12
2. DISCREPANCY REPORTING..................................................................................................................................... 13
2.1 Operator’s Initial Report ....................................................................................................................................... 13
2.2 PEMCO Follow Up Action.................................................................................................................................... 13
3. DOCUMENT USAGE AND DETAILED INSPECTION FORM (DIF) EXAMPLE ......................................................... 14
3.1 General Instructions ............................................................................................................................................. 14
4. DEFINITION OF INSPECTION METHODS ................................................................................................................ 15
4.1 Visual Inspection .................................................................................................................................................. 15
4.2 Fluorescent-Penetrant (F-P) Inspection .............................................................................................................. 15
4.3 Eddy Current Inspection ...................................................................................................................................... 15
4.4 Detailed Inspection Form (DIF)............................................................................................................................ 16
4.4.1 Example Detailed Inspection Form ................................................................................................................. 17
4.4.2 Example Job Card ........................................................................................................................................... 18
5. LIST OF AIRWORTHINESS DIRECTIVES AND SERVICE BULLETINS ................................................................... 19
6. DETAILED INSPECTIONS .......................................................................................................................................... 20
6.1 Effective Aircraft ................................................................................................................................................... 20
6.2 Inspection Summary ............................................................................................................................................ 21
6.2.1 Inspection Summary – General Interior and Exterior and Cargo Door ........................................................... 21
6.2.2 Inspection Summary – External Doubler and Upper Jamb ............................................................................. 22
6.2.3 Inspection Summary – Lower Jamb and Hinge .............................................................................................. 23
6.2.4 Inspection Summary – Hydraulic, Static Ports, and Cargo Compartment Liner Installations ......................... 24
6.2.5 Cargo Door - Location ..................................................................................................................................... 25
6.2.6 Cargo Door Surround Structure - Location ..................................................................................................... 26
7. DETAILED INSPECTION FORMS .............................................................................................................................. 27
7.1 Internal Structure – Visual Inspections ................................................................................................................ 27
7.1.1 Internal Inspection, IN-1 .................................................................................................................................. 28
7.1.2 Internal Structure, IN-2 .................................................................................................................................... 32
7.1.3 Internal Structure, IN-3 .................................................................................................................................... 35
7.2 External Structure – Visual Inspections ............................................................................................................... 41
7.2.1 External Structure, EX-1 .................................................................................................................................. 42
7.3 External Doubler .................................................................................................................................................. 46
7.3.1 External Doubler Installation, ED-1 ................................................................................................................. 47
7.3.4 External Doubler Installation, ED-4 and ED-5 ................................................................................................. 60
7.4 Cargo Door .......................................................................................................................................................... 85
7.4.1 Cargo Door Installation, CD-1 Through CD-4 ................................................................................................. 86
7.5 Upper Jamb ......................................................................................................................................................... 97
7.5.1 Upper Jamb Installation, UJ-1 ......................................................................................................................... 98
7.5.2 Upper Jamb Installation, UJ-2 ....................................................................................................................... 103
7.5.3 Upper Jamb Installation, UJ-3 ....................................................................................................................... 110
7.6 Lower Jamb ....................................................................................................................................................... 114
7.6.1 Lower Jamb Installation, LJ-1........................................................................................................................ 115
7.6.2 Lower Jamb Installation, LJ-1A ..................................................................................................................... 119
7.6.3 Lower Jamb Installation, LJ-2........................................................................................................................ 123
05-30-10
Feb. 11, 2015
TABLE OF CONTENTS
7.7 Hinge Assembly ................................................................................................................................................. 127

7.7.1 Hinge Assembly Installation, HINGE-1.......................................................................................................... 128
7.8 Frame Modification ............................................................................................................................................ 133
7.8.1 Frame Modification, FRAME-1 ...................................................................................................................... 134
7.9 14 CFR 26.47..................................................................................................................................................... 137
7.9.1 Hydraulics Installation, HY-1 ......................................................................................................................... 138
7.9.5 Smoke Detector Static Port, SP-1 ................................................................................................................. 152
7.9.6 Smoke Detector Static Port, SP-2 ................................................................................................................. 158
7.9.7 Cargo Compartment Liner, CC-1 .................................................................................................................. 162
7.9.10 Cargo Compartment Liner, CC-4 .............................................................................................................. 174
8. INSPECTION COUPONS .......................................................................................................................................... 189
8.1 Coupon Number 2 ............................................................................................................................................. 190
8.2 Coupon Number 3 ............................................................................................................................................. 191
8.3 Coupon Number 6 ............................................................................................................................................. 192
8.4 Coupon Number 12 ........................................................................................................................................... 193
8.5 Coupon Number 25 ........................................................................................................................................... 194
8.6 Coupon Number 29 ........................................................................................................................................... 195
8.7 Coupon Number 31 ........................................................................................................................................... 196
APPENDIX A - Eddy Current, Fuselage Skin Surrounding the Main Deck Cargo Door
APPENDIX B - Eddy Current, Fuselage Skin Surrounding the Main Deck Cargo Door, (External Splice Plate Areas)
05-30-10
Feb. 11, 2015
1. STRUCTURAL INSPECTION
This section of the document contains the requirements of the structural inspections that are required.
1.1 Purpose
The purpose of Structural Inspections is to ensure the continuing structural airworthiness of the Pemco B737-
200/300/400 QC/F and B737-400 Freighter-Passenger Combi as modified per PEMCO Supplemental Type
Certificates. The scope of this inspection includes the main deck cargo door and the surrounding fuselage
structure.
It is important to realize that:
o This inspection identifies Principle Structural Elements (PSE's) having potential crack growth initiation
warranting special attention and requiring inspection to assure timely detection of damage.
o The inspection requirements are based on the premise that operators are applying and will continue to
apply an approved structural inspection program for identification of cracks, corrosion and other forms of
damage on their subject aircraft.
Revision 12 of this document contains a series of new inspections that have been incorporated based on the
requirements of 14 CFR 26.47 (see page 24) and satisfies the structural requirements of 14 CFR part 26.
Revision 13 of this document contains a new inspection that addresses an eleven (11) cargo pallet modification
for 737-400 aircraft only that has been incorporated as an amendement to the existing supplemental type
certificate.
05-30-10
Feb. 11, 2015
1.2 Introduction
The Pemco B737-200/300/400 QC/F is a baseline B737-200/300/400 with a main deck cargo door installed on
the forward left side of the fuselage. The Pemco B737-400 Passenger-Freighter Combi is a baseline B737-400
with a main deck cargo door installed on the forward left side of the fuselage. These changes are the same as
the QC/F modifications. The B737-400 Passenger-Freighter Combi incorporates a Halon fire suppression
system, a main deck partition, and the floor remains unchanged aft of FS 612. The incorporation of the Halon fire
suppression system and the main deck partition require additional structural inspection requirements beyond
those required for the B737-200/300/400 QC/F as indicated by the inspections given in IN-3.
Due to the significant structural changes and characteristics of this type of modification, the main deck cargo door
and the surrounding fuselage are highly loaded areas. This structural inspection was developed in order to
maintain continued airworthiness over the expected life of the aircraft. A general overview of the inspection areas
are shown in sections 6.2.5 (page 25) and 6.2.6 (page 26).
requirements of 14 CFR 26.47 (see page 24) and satisfies the structural requirements of 14 CFR part 26. For
aircraft already in service at the time of the issuance of Revision 12 of this document, inspections are to begin
within 4,000 flights, or before December 31, 2012, whichever occurs first.
Revision 12 of this document contains a new inspection (ED-9) that has been incorporated based on service data
collected.
PEMCO P03-218MM was a supplemental inspection document that contained additional inspection requirements
to PEMCO P03-007MM, revision 10. The additional inspections were based on a fatigue and damage tolerance
evaluation for the critical STC structure in accordance with the requirements of 14 CFR 26.47. The requirements
in the PEMCO P03-218MM were evaluated and are now included in PEMCO P03-007MM, Revision 12. PEMCO
P03-218MM has subsequently been cancelled and is no longer required as part of aircraft maintenance.
The compilation of this structural inspection involved:
o The identification of structural parts or components which contribute significantly to carrying flight, ground
or pressure loads whose failure could affect the structural integrity necessary for the safety of the airplane
and whose damage tolerance or safe-life characteristics is necessary, therefore, to establish or confirm.
These are called Principle Structural Elements (PSE's).
o The calculation of residual strength, with continued growth damage and interactive crack growth under
typical flight and ground loading, such that the airplane structure can sustain the load conditions stated for
fail-safe qualification under 14 CFR 25.571(b), amendment level 119.
o The establishment of a procedure for developing inspections that provide a high probability of detecting
fatigue damage before residual strength falls below the above noted fail-safe requirements.
o This includes the inspection of Principle Structural Elements (PSE's) with known fatigue problems and
PSE's with no history of in-service fatigue cracking. Known fatigue problems which could affect the
structural integrity necessary for safety of the airplane, that are covered by existing Service Bulletins
(SB's) or Airworthiness Directives (AD's), have been reassessed. A list of SB's and AD's with flight safety
implications are listed in section 5 (page 19).
o This inspection utilizes the Detailed Inspection Form (DIF). This form contains physical details on the area
of inspection along with the method of inspection and space for recording and documenting results and
deviations from approved design data. A Detailed Inspection Form exists for each unique area of
inspection.
Revision 13 of this document contains new inspections that are part of an amendment to supplemental type
certificate SA2968SO that allows an eleven (11) cargo pallet modification for 737-400 aircraft only for the full
freighter conversation after modification to the FS1006 frame.
05-30-10
Feb. 11, 2015
1.3 Principal Structural Elements (PSE’s)
The two design principles for obtaining structural safety are "damage tolerance" and "safe-life". Damage tolerance
relies on some means of detecting damage before airplane safety is jeopardized. This is the preferred design principle
whenever practical.
In order to determine safety analysis requirements and corresponding maintenance considerations, airplane structure
can be categorized as primary (structurally significant) or secondary. This breakdown is a determination of an item's
function in relation to structural integrity. Any detail, element or assembly, which contributes significantly to carrying
flight, ground, or pressure loads and whose failure could affect the structural integrity necessary for the safety of the
airplane, is classified as a principle structural element (PSE). Items not in this category are classified as secondary or
other structure.
The structural integrity of the damage tolerant primary structure is assured by timely damage detection with a planned
inspection program. For fatigue damage, inspection requirements are matched to structural characteristics that
include residual strength, crack growth rate and damage detection. The parameters considered in determining the
damage tolerant PSE's for this structural inspection include:
o Consequence of cracking
o Inspectability
o Stress environment
o Multiple cracking
o Structural redundancy
Several cracking patterns were considered for each PSE to determine the most critical. This generally resulted in a
crack origin being considered in a location difficult to inspect
The PSE’s are addressed by the Detailed Inspection Forms. An explanation of a Detailed Inspection Form is given in
sections 4.4 and 4.4.1 (pages 16 and 17).
05-30-10
Feb. 11, 2015
1.4 Fatigue Critical Alteration Structure (FCAS)
For 14 CFR 26, paragraph 26.49 compliance, PEMCO identified the fatigue critical alteration structure (FCAS) in
Revision A, dated 30 July 2009, of Report 5039 titled “14 CFR Part 26.49 FCAS Compliance” for PEMCO
supplemental type certificates.
Data from Report 5039 is included below to identify the fatigue critical alteration structure that has been created by the
installation of PEMCO supplemental type certificate SA2969SO.
Description Location
Between Fuselage Stations 360 and 500, Between Stringer
Main Cargo Door - Skin
3½L and 18L
Between Fuselage Stations 360 and 500, Between Stringer
Main Cargo Door - Frames
3½L and 18L
Between Fuselage Stations 360 and 500, At Stringer 18L
Main Cargo Door – Latch Fittings
(Lower Edge of Main Cargo Door)
Forward - Between Fuselage Stations 370 and 380,
Between Stringer 4L and 7L
Main Cargo Door – Forward & Aft Actuator
Fittings
Aft - Between Fuselage Stations 480 and 490, Between
Stringer 4L and 7L
Between Fuselage Stations 360 and 500, At Stringer 3½L
Main Cargo Door – Hinge Assembly
(Upper Edge of Main Cargo Door)
Main Cargo Door Surround Structure – Latch Between Fuselage Stations 360 and 500, At Stringer 18L
Fittings (Lower Sill)
Main Cargo Door Surround Structure – Upper Between Fuselage Stations 312 and 500B, At Stringer 2R,
Jamb Installation 2L, and 3½L
Main Cargo Door Surround Structure – Modified Fuselage Frames Between Fuselage Stations 312
Forward Jamb Installation and 360, Between Stringer 2R and 25L
Main Cargo Door Surround Structure – Lower Between Fuselage Stations 312 and 500B, At Stringer 18L
Jamb Installation and 23L
Main Cargo Door Surround Structure – Aft Modified Fuselage Frames Between Fuselage Stations 500
Jamb Installation and B00B, Between Stringer 5R and 28L
Main Cargo Door Surround Structure – Fuselage Skin and Doubler Between Fuselage Stations 312
External Doubler Installation and 500B and Between Stringers 3R and 23L
Modified Floor Beams Between Fuselage Stations 295 and
Transverse Floor Beams
540, and Between Fuselage Stations 727 and 1036
Modified Floor Beams Between Fuselage Stations 540 and
Longitudinal Floor Beams
727
05-30-10
Feb. 11, 2015
2. DISCREPANCY REPORTING
All cracks involving a PSE or related structure in close vicinity to the PSE shall be reported promptly (within 5 working
days) to Pemco. There is no requirement to report completed inspections if no discrepancies or deviations from
approved design data have been detected.
2.1 Operator’s Initial Report

Upon recognition of a PSE discrepancy, the following information should be faxed or e-mailed to Pemco.
Subject: ATTENTION - PSE DISCREPANCY
 PSE description and location
 Airplane serial number on which discrepancy was found
 Flight cycles and hours on damaged item
 Location and description of damage including direction and size
 When discovered and inspection method used
E-mail to shannon.trail@pemcoair.com
Contact Pemco Product Support at:

Product Support Coordinator
Pemco World Air Services
4102 N. Westshore Blvd
Tampa, FL 33614
Contact Phone Numbers: (813)-322-9600 Ext: 9829 or (334)-648-1012
2.2 PEMCO Follow Up Action

All adverse PSE reports will be reviewed promptly, within 48 hours, to determine if there are findings directly
applicable to the PSE being addressed. If discrepancies are related to the PSE, the following actions will be taken:
o Factual data available on each finding will be reported, with appropriate priority, to operators and airworthiness
authorities.
o If required, a fleet inspection program will be developed to obtain additional data necessary to formulate a service
bulletin.
o A service bulletin addressing recommended structural modifications and inspections may be issued.
05-30-10
Feb. 11, 2015
3. DOCUMENT USAGE AND DETAILED INSPECTION FORM (DIF) EXAMPLE
The following instructions apply to the Pemco B737-300/400 QC/F and the B737-400 Freighter-Passenger Combi
Structural Inspections. Approval and monitoring of the resulting program is the responsibility of the regulatory agency
for each operator.
3.1 General Instructions

Operators of all subject aircraft shall complete all applicable inspections for each PSE in sections 6 and 7 (pages 20
and 27).
Standard maintenance practices should not be relaxed without considering the requirements for timely-detection of
corrosion, stress corrosion, or accidental damage.
This section defines inspections for PSE's that may conflict with an existing Service Bulletin or Airworthiness
Directives. For these situations, this section shall take precedence.
Inspection intervals are in flight cycles (Ground Air Ground). Full stop landings during training shall be treated as flight
cycles. Two touch and go training flights are considered equivalent to one flight cycle.
o For the inspections contained within this document, cycles listed are cycles after the floor beam, forward
cargo door, and class “E” modifications (PEMCO 737-200/300/400 QC/F conversions).
o For the inspections contained within this document, cycles listed are cycles after the floor beam, forward
cargo door, and class “C” modifications (PEMCO 737-400 Freighter-Passenger conversions).
o All other inspections not contained in this document remain on their existing inspection cycle.
To minimize manpower requirements, details with similar repeat intervals, common access or other similarities can be
grouped into packages. The repeat interval for the package shall be no greater than the shortest repeat interval for
any PSE in the package.
The principal structural details and anticipated critical cracking pattern for each PSE are shown in the diagram on the
Detailed Inspection Form. The cracking pattern shown is not necessarily the pattern that may occur. For example, a
crack may originate in the opposite side of a PSE to the one shown. Therefore, all visible parts of the PSE detail(s)
should be inspected. The inspection options shown for each PSE provide adequate opportunity for detecting fatigue
damage from any pattern. A visual inspection of exposed adjacent structure shall be conducted during inspection of a
given PSE, and is intended to include those primary structural members adjacent to the PSE detail area boundary that
are within the scope of the inspector's vision to perform a proper visual inspection without additional effort in terms of
access or physical relocation. Include results with regards to the visual inspection on the comment section of the
Detailed Inspection Form.
Operators must assess the visibility of each PSE being inspected relative to the assumed normal condition shown in
the sketches and diagrams in this document, based on normal airplane manufacturing, inspection and maintenance
practices.
o Alternate inspection methods are required if any obstructions, not part of normal condition such as
installed repair or equipment, cannot be removed prior to inspection. If assistance is required, contact
Pemco per section 2.1 (page 13) and provide details.
o Production applied sealant and corrosion protection finishes shall be removed only when specified.
Inspection arrows are used to identify applicable inspection directions for each zone. For surveillance or detailed
inspections, all visible parts of the PSE details should be inspected. For example, if the structure detail is a stringer all
visible parts of the stringer should be inspected. For Nondestructive Test (NDT) inspections, the arrows indicate the
general location of the inspection.
PSE inspections may not apply to areas which have been repaired. Contact Pemco per section 2.1 (page 13),
regarding applicability by providing repair details/date and advise if Pemco was involved with design approval or
installation.
05-30-10
Feb. 11, 2015
4. DEFINITION OF INSPECTION METHODS
4.1 Visual Inspection

The visual inspection is a close intensive inspection of highly defined structural details searching for evidence of
structural irregularities and discrepancies such as wear, deterioration, damage, corrosion, cracking, etc. Adequate
lighting is required and where necessary, inspection aids such as mirrors should be used. Surface cleaning and
access procedures may be required to gain proximity. These inspections are to take place a distance considered
adequate (typically less than 3 feet) to view the structure indicated in the inspection documents.
For difficult to access areas it is permissible to utilize visual aids, bore scopes, mirrors, optical enhancement
equipment, etc…..
4.2 Fluorescent-Penetrant (F-P) Inspection

The F-P inspection is used to find surface cracks that may be too small for detection by the naked eye. The area of
inspection must be stripped clean of paint, sealant, grease, etc…. A liquid containing a fluorescent material is applied
to the part to be inspected and is allowed to penetrate cracks, laps and other discontinuities. The part is then washed
with a suitable solvent and dried, after which a developing powder is applied to draw the penetrant to the surface.
Excess powder is brushed off, and the part is examined under ultraviolet light. Cracks and other flaws are revealed as
fluorescent markings.
For Fluorescent-Penetrant Inspections, reference Boeing 737 NDT Manual D6-37239.
4.3 Eddy Current Inspection

Eddy current testing has gained a reputation as one of the most versatile and reliable inspection methods available.
To initiate eddy currents in a test object, an alternating current of selected frequency is applied to a test coil. The
alternating current produces a varying magnetic field called the primary field around the test coil. When the test coil is
placed next to a metal part, the primary magnetic field causes eddy currents to flow in the part. The depth to which the
flow of eddy currents penetrates varies inversely with material conductivity and with the frequency applied to the test
coil. This flow of eddy currents generates a second magnetic field, which affects the initial field from the coil. The
resultant magnetic field determines the coil electrical characteristics and becomes the source of information, which is
analyzed electronically to yield the required data. The condition of the part is determined from this data. Material
properties that can be detected from eddy current instrumentation include; cracks, pits, porosity, voids, inclusions and
seams.
Normally it is not necessary to disassemble or remove a part from the airplane for eddy current inspection. Parts
being inspected require only minimum cleaning before inspection. Eddy current inspection can be performed through
paint, oil, or any uniform non-conducting material.
Eddy current applications are generally classified as High Frequency (Surface Inspection) or Low Frequency
(Subsurface Inspection). Frequencies above 50 kHz are generally considered high frequency. High frequencies are
used to inspect for cracks or similar defects that are open to or just below an accessible surface. This includes
fastener hole inspection with the fastener removed and a wide variety of surface crack inspections. Frequencies
below 50 kHz are considered low frequency. Low frequencies are used to inspect for subsurface cracks or cracks in
underlying structure using probes and equipment specifically designed for low frequency applications. Low frequency
inspections generally require the use of reference standards. These standards are models of the built up structure
being inspected and have known cracks in them. The eddy current instrumentation is calibrated with these reference
standards so the inspector will know what the instrumentation response will be if a crack is detected during the actual
inspection. Appendices A and B contain information on the procedures, probes, and reverence standards developed
for this modification. Section 9 contains coupons representative of the aircraft structure.
For Eddy Current Inspections, reference Boeing 737 NDT Manual D6-37239.
05-30-10
Feb. 11, 2015
4.4 Detailed Inspection Form (DIF)
The detailed inspection form is used to document the required inspections. The following example illustrates how a
form should be filled out. See Sample Detailed Inspection Form given on page 17.
1. Item: Identifies the inspection area. Refer to the top drawing of each inspection area for location
identification. The following prefixes are used to isolate the inspection area.
o ED - External Doubler
o LJ - Lower Jamb
o UJ - Upper Jamb
o FJ - Forward Jamb
o AJ - Aft Jamb
o CD - Cargo Door
2. Description: Gives a brief description of the area being inspected.

3. Operator: Current operator of the subject aircraft.
4. S/N: Aircraft serial number as listed on the aircraft identification plate.
5. Large arrows show typical inspection directions and methods.
6. Fastener location circled for inspected fasteners with no damage found at that location.
7. Fastener location circled and crossed out if damage is suspected.
8. Indicates fastener column number for reference purposes.
9. Indicated fastener row number for reference purposes. Only labeled rows require inspection.
10. Structure: Identifies areas of similar inspection requirements for the subject inspection detail.
11. Job Card: This is for the operator's use to record inspection results.
o Sample Job Cards are supplied with this document; operator’s use of these job cards is optional.
12. Method (NDT): Identifies the method of inspection to be used.

o LFEC - Low Frequency Eddy Current
o HFEC - High Frequency Eddy Current
o FP - Fluorescent Penetrant
o V - Visual
13. Coupon No.: Identifies the reference standard to be used on the indicated areas for LFEC inspections.
Section 8 (page 189) contains details on all coupons. Appendices A and B contains reference standards,
procedures, and probe information.
14. Post Modification Flight Cycles: Indicates number of flight cycles on the modified airframe structure at the
time of inspection.
15. NiT : Inspection threshold. The maximum number of flight cycles allowed before the first inspection. The
inspection may be performed any time prior to the maximum number of flights.
16. Ni : Inspection interval. The maximum number of flight cycles allowed between subsequent inspections
after the initial inspection.
17. Comments: Document deviations in fastener pattern, and other discrepancies found during the
inspection.
18. ID Number: Inspectors identification/certification number.
o Sample Job Cards are supplied with this document; operator’s use of these job cards is optional.
05-30-10
Feb. 11, 2015
4.4.1 Example Detailed Inspection Form
ITEM: MODEL-SERIES:
DETAIL INSPECTION ED-1-5 1
B737-200/300/400
FORM SHEET __1__ OF __1__
DESCRIPTION: OPERATOR: S/N:
DOUBLER INSTALLATION STR-3R 2 3 4
5 8
6 7
11 12 13 14 15 16
STRUCTURE COUPON NiT Ni
POST MOD
JOB METHOD No.
FLIGHT
CARD (NDT)
10 CYCLES FLIGHTS
RIVETS, R1C1-R1Ci LFEC 8000 4000

1
RIVETS, R2C1-R2Ci LFEC 8000 4000
17 1
COMMENTS: __________USE S-3R LFEC PROCEDURE IN APPENDIX A_____________________
__________________________________________________________________________________
__________________________________________________________________________________
18
ACCOMPLISHED BY: _____________________________________________________
(SIGNATURE ID NUMBER DATE)
INSPECTOR: _____________________________________________________
Figure 1: Sample Detailed Inspection Form
05-30-10
Feb. 11, 2015
4.4.2 Example Job Card
FLIGHT CYCLES ITEM: MODEL-SERIES:

ED-1-5
JOB CARD B737-200/300/400
SHEET __1 _ OF __1 _
DOUBLER INSTALLATION STR-3R
RESULTS:
ROW COLUMN ROW COLUMN ROW COLUMN
REPORT POSITIVE CRACK INDICATION AT ROW # AND COLUMN # APPROPRIATE
COMMENTS: _____ USE S-3R LFEC PROCEDURE IN APPENDIX A ________________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
Figure 2: Sample Job Card
05-30-10
Feb. 11, 2015
5. LIST OF AIRWORTHINESS DIRECTIVES AND SERVICE BULLETINS
The Service Bulletins and Airworthiness Directives listed below apply to Principle Structural Elements (PSE's) for
which in-service fatigue cracking has been found. These documents are listed for reference purposes only.
NOTE: See latest revision of listed document.
Document Title
ASL A737-52-0009 Hinge Inspection of Main Cargo Door (MCD)
SB 737-52-0012 Main Cargo Door Lower Fwd and Aft Hinge Shim/Fairing Replacement
ASL A737-52-0019 Frame Inspection of Main Cargo Door (MCD)
SB 737-52-0019 Main Cargo Door Frame and Upper Beam Cracks - Repair Of
SB 737-52-0033 Door- Replacement of Main Cargo Door and Upgrade Surround Structure
SL 737-52-0030 Door - Main Cargo Door Frame Inspection
Fuselage, Main Cargo Door Surround Structure, Cracks in Lower Jamb Latch Fitting
SB 737-53-0003
Angles, Inspection Of
SB 737-29-0011 Hydraulic Power – MCD Hydraulic System and Control Panel Upgrade
Fuselage, Main Cargo Door Surround Structure, Crack in Existing Frame to Lower
ASL 737-53-0004
Sill Tie Down
AD 94-12-12 References PEMCO SB 737-52-0012
AD 95-01-06 R1 References PEMCO SB 737-53-0003
AD 95-06-05 References PEMCO ASL 737-53-0004
Inspection of MCD Upper Frames and Upper Jamb of Fuselage to detect cracks in
AD 98-04-41
Hinge and Lift Actuator Box Area of MCD and Upper Jamb Area.
Life limits MCD Lower Frames and Angles to 7,000 FC
AD 2001-08-07
Reference PEMCO SB 737-52-0037 (Superseded by AD 2004-03-23)
Mandates replacement of Lower Jamb Latch Lug Support Angles.
AD 2001-09-15
Reference PEMCO SB 737-53-0003
Life limits MCD Lower Frames and Angles to 7,000 FC
AD 2004-03-23 Reference PEMCO SB 737-52-0037 (Supersedes AD 2001-08-07)
Note: If AD 2001-08-07 not required then AD 2004-03-23 not required
Jetaire [1]
SB B737-26-8016 Inspection Details & Intervals
9002C0013 Instructions For Continued Airworthiness
TABLE 1: Airworthiness Directives and Service Bulletins

[1] Jetaire STC installation incorporated within PEMCO alteration
05-30-10
Feb. 11, 2015
6. DETAILED INSPECTIONS
This section contains a summary of the required inspections and aircraft effectivity.
6.1 Effective Aircraft

All 737-200, 737-300 and 737-400 QC/F aircraft and all 737-400 Freighter-Passenger aircraft modified in accordance
with PEMCO Supplemental Type Certificates.
requirements of 14 CFR 26.47 (see page 24) and satisfies the structural requirements of 14 CFR part 26.
05-30-10
Feb. 11, 2015
6.2 Inspection Summary
See sections 6.2.5 and 6.2.6 (pages 25 and 26) for an overview of the area affected by this modification.
6.2.1 Inspection Summary – General Interior and Exterior and Cargo Door
Revision 12 (and later approved versions) of this document contains a series of new inspections that have been
incorporated based on the requirements of 14 CFR 26.47 (see section 6.2.4, page 24) and satisfies the structural
requirements of 14 CFR part 26.
Inspection Threshold[3] Inspection Interval Min. Crack

Inspection Item Description Inspection Method
NT Cycles Ni (Cycles) (in)
AREA OF MODIFICATION
GENERAL AREA OF MODIFICATION
IN-1 Interior of Aircraft FS 312 to FS 500B, Stringer 3R to 23L 16000 16000 DET VISUAL 1.00
IN-2 Transverse Floor Beams, Sections 43 and 46 [6] 16000 16000 DET VISUAL 1.00
IN-3 [4] Interior of Aicraft – Combi Modifications 16000 16000 DET VISUAL 1.00
EX-1 Exterior of Aircraft FS 312 to FS 500B, Stringer 3R to 23L 4000 4000 DET VISUAL 1.00
MAIN CARGO DOOR [1] [2] [5]
CD-1 Fitting [1] [5] 8000 8000 DET VISUAL 1.00
CD-1 Fitting Surface [1] [5] 32000 32000 DET VISUAL 1.00
CD-1 Fitting Fastener Holes [1] [5] 32000 32000 HFEC 0.05X0.05
CD-2 Fitting [1] [5] 8000 8000 DET VISUAL 1.00
CD-2 Fitting Surface [1] [5] 32000 32000 DET VISUAL 1.00
CD-2 Fitting Fastener Holes [1] [5] 32000 32000 HFEC 0.05X0.05
CD-3 MCD Upper Fitting Fastener Holes [1] [5] 32000 32000 HFEC 0.05X0.05
CD-3 MCD Upper Fitting [1] [5] 16000 16000 DET VISUAL 1.00
CD-4 MCD Latch Assy, Fastener Holes [2] 32000 32000 HFEC 0.05X0.05
[1] Aircraft that have not incorporated Service Bulletin 737-52-0033 (installing fitting for the cargo door and upper jamb) or were
not modified after March 11, 2001 are still subject to the requirements of AD 98-04-41. Aircraft subject to the requirements
of AD 98-04-41 are also subject to additional inspections similar to those specified by CD-1 and CD-2.
[2] Aircraft that have not incorporated Service Bulletin 737-52-0033 or were modified prior March 11, 2001 are still subject to the
requirements of AD 2004-03-23.
[3] For the inspections contained within this document, cycles listed are cycles after the forward cargo door, floor beam, and
class “E” modifications (for the 737-200/300/400 QC/F) or class “C” modifications (for 737-400 Passenger-Freighter Combi).
Inspections may be carried out prior to requirements listed above to facilitate existing aircraft maintenance.
[4] IN-3 is applicable to 737-400 Combi airplanes only.
[5] CD-1 through CD-4 apply to aircraft that have installed PEMCO Service Bulletin 737-52-0033 or were modified after March
11, 2001. Aircraft subject to the requirements of AD 98-04-41 are also subject to additional inspections similar to those
specified by CD-1 and CD-2.
[6] Inspect in accordance with D6-37089 and D6-82669 between FS540 and FS727B, with the exception of F-46. PEMCO
Service Bulletins (SB’s) 737-57-0001, 737-57-0002, and 737-53-0026 developed to address Boeing Airworthiness Directives
in this area.
05-30-10
Feb. 11, 2015
6.2.2 Inspection Summary – External Doubler and Upper Jamb

AREA OF MODIFICATION
EXTERNAL DOUBLER [4]
ED-1 Upper Jamb @ Str 3R [4] [7] 8000 4000 LFEC 0.18/0.125
ED-2 Lower Jamb @ Str 23L [4] [7] 8000 4000 LFEC 0.18/0.125
Aft Jamb @ STA 500B Stringer 3R to 14L [4] 16000 8000 LFEC 0.15
ED-3
Aft Jamb @ STA 500B Stringer 14L to 23L [4] 32000 16000 LFEC 0.15
ED-4 Fwd Jamb @ STA 312 Stringer 3R to 7L [4] 16000 8000 LFEC 0.15
ED-5 Fwd Jamb @ STA 312 Stringer 18L to 23L [4] 32000 16000 LFEC 0.15
ED-6 Upper Jamb, Splices [4] [7] 8000 4000 LFEC 0.28/0.26
ED-7 Lower Jamb, Splices [4] [7] 8000 4000 LFEC 0.28/0.26
Aft Jamb, Splices (3R to 14L) [4] 16000 8000 LFEC 0.28/0.26
ED-8
Aft Jamb, Splices (14L to 23L) [4] 32000 16000 LFEC 0.28/0.26
FS 350- 370 & FS490-510, Between S-3L and S-4L, FS 350-370 & General HFEC & 0.1250
ED-9 [8] 8000 4000
FS490-510, Between S-17L and S-18L HFEC @ Fastener 0.0625
FS 350- 370 & FS490-510, Between S-3L and S-4L, FS 350-370 &
ED-9 [8] 2000 2000 DET VISUAL 1.00
FS490-510, Between S-17L and S-18L
EXTERNAL DOUBLER [5]
ED-1 Upper Jamb @ Str 3R [5] [7] 20000 4000 LFEC 0.18/0.125
ED-2 Lower Jamb @ Str 23L [5] [7] 20000 4000 LFEC 0.18/0.125
Aft Jamb @ STA 500B Stringer 3R to 14L [5] 20000 8000 LFEC 0.15
ED-3
Aft Jamb @ STA 500B Stringer 14L to 23L [5] 32000 16000 LFEC 0.15
ED-4 Fwd Jamb @ STA 312 Stringer 3R to 7L [5] 20000 8000 LFEC 0.15
ED-5 Fwd Jamb @ STA 312 Stringer 18L to 23L [5] 32000 16000 LFEC 0.15
ED-6 Upper Jamb, Splices [5] [7] 20000 4000 LFEC 0.28/0.26
ED-7 Lower Jamb, Splices [5] [7] 20000 4000 LFEC 0.28/0.26
ED-8 Aft Jamb, Splices (3R to 14L) [5] 20000 8000 LFEC 0.28/0.26
ED-8 Aft Jamb, Splices (14L to 23L) [5] 32000 16000 LFEC 0.28/0.26
FS 350- 370 & FS490-510, Between S-3L and S-4L, FS 350-370 & General HFEC & 0.1250
ED-9 [8] 8000 4000
FS490-510, Between S-17L and S-18L HFEC @ Fastener 0.0625
FS 350- 370 & FS490-510, Between S-3L and S-4L, FS 350-370 &
ED-9 [8] 2000 2000 DET VISUAL 1.00
FS490-510, Between S-17L and S-18L
UPPER JAMB [2]
UJ-1 Frame clips @ STR 2L between STA 370 & STA 489 [1] [6] 4000 4000 LFEC 0.10
UJ-1 Frame clips @ STR 2L between STA 370 & STA 489 [1] [6] 4000 4000 HFEC 0.05X0.05
UJ-2 Pemco to Boeing frame splices between STA 312 & STA 500B [9] 8000 8000 HFEC 0.10
Upper Jamb Fitting [2] 32000 32000 HFEC 0.05X0.05
UJ-3
Upper Jamb Fitting [2] 16000 16000 DET VISUAL 1.00
[1] Aircraft that have incorporated Service Bulletin 737-52-0033 (installing upper jamb inner skin) or have been modified after
March 11, 2001 are not subject to the inspections given in UJ-1.
[2] Aircraft that have not incorporated Service Bulletin 737-52-0033 (installing fitting for the cargo door and upper jamb) or were
not modified after March 11, 2001 are still subject to the requirements of AD 98-04-41.
[4] Production changes were incorporated as part of 007-00120, Revision A that specified HFEC eddy current of fastener holes
prior to installation of the doubler. Aircraft delivered prior to December 31, 2005 do not incorporate these production
changes and are subject to these inspections.
[5] Production changes were incorporated as part of 007-00120, Revision A that specified HFEC eddy current of fastener holes
prior to installation of the doubler. Aircraft delivered after December 31, 2005 incorporate these production changes and are
subject to these inspections.
[6] Either the LFEC inspection or the HFEC inspection may be performed. HFEC inspection requires fastener removal.
[7] It is permissible to perform these inspections from aircraft interior, see task cards for detailed information.
[8] ED-9 Applies to all aircraft.
[9] Fastener removal required at FS312 and FS328, removal may be required at other locations.
05-30-10
Feb. 11, 2015
6.2.3 Inspection Summary – Lower Jamb and Hinge

LOWER JAMB [1] & [2]
LJ-1 Lower Jamb Fitting Connection – FS 369.21 to FS 490.80 [2] [3] 0 8000 HFEC 0.05X0.05
LJ-1A Lower Jamb Fitting Connection – FS 369.21 to FS 490.80 [2] 32000 16000 HFEC 0.05X0.05
LJ-2 Lower Jamb Fitting Connection – FS 369.21 to FS 490.80 32000 32000 HFEC 0.0625
HINGE [5]
HINGE-1 Hinge Assy [5] 4000 4000 DET VISUAL 1.00
HINGE-1 Steel Hinge Assy [5] 4000 4000 HFEC 0.125x0.125
HINGE-1 Aluminum Hinge Assy [5] 20000 32000 HFEC 0.125x0.125
HINGE [6]
HINGE-1 Hinge Assy [6] 4000 4000 DET VISUAL 1.00
HINGE-1 Steel Hinge Assy [6] 20000 4000 HFEC 0.125x0.125
HINGE-1 Aluminum Hinge Assy [6] 20000 32000 HFEC 0.125x0.125
FRAME [7]
FRAME-1 FS1006 Frame [7] 8,000 8,000 DET VISUAL 1.00
FRAME-1 FS1006 Frame [7] 4,000 4,000 DET VISUAL 1.00
[1] The Lower Jamb to Boeing Frame Splice area was subject to AD 95-06-05. Aircraft that have incorporated Service Bulletin
737-52-0033 (installing part number 007-00522-5/-7) or have been modified after March 11, 2001 are not subject to the
requirements of AD 95-06-05.
[2] Aircraft modified prior to March 11, 2001 are subject to AD-2001-09-15, which mandated replacement of the Lower Jamb
Latch Lug Support Angles and are subject to the inspections specified in AD-2001-09-15 if PEMCO SB 737-53-0003 or 737-
53-0004 have NOT been incorporated. Aircraft that have been modified prior March 11, 2001 AND that have incorporated
PEMCO SB 737-53-0003 or 737-53-0004 (Alternative Means of Compliance to AD 2001-09-05) are subject to the
inspections specified in LJ-1. Aircraft that have been modified after March 11, 2001 are subject to the inspections specified
in LJ-1A.
[3] A grace period of 50 cycles is acceptable for initial inspections for LJ-1.
[5] Production changes were incorporated as part of 007-00602, Revision F that specified an increased radius at the “fingers” of
the hinge. Aircraft delivered prior to December 31, 2005 do not incorporate these production changes and are subject to
these inspections.
[6] Production changes were incorporated as part of 007-00602, Revision F that specified an increased radius at the “fingers” of
the hinge. Aircraft delivered after December 31, 2005 incorporate these production changes and are subject to these
inspections.
[7] Only 737-400 aircraft modified in accordance with an amendment to supplemental type certificate (STC) SA2968SO that
allow an eleven (11) cargo pallet modification are subject to these inspections.
05-30-10
Feb. 11, 2015
6.2.4 Inspection Summary – Hydraulic, Static Ports, and Cargo Compartment Liner Installations
The inspections added as part of the 14 CFR 26.47 requirements at Revision 12 are included in this section. These
additional inspection satisfies the structural requirements of 14 CFR part 26.
Hydraulic System Installations
HY-1 Wheel Well Bulkhead – FS 727, LBL 23.5 [5] 4000/500 [3] 4000/500 [3] DET VISUAL 1.00
HY-2 Aft Pressure Bulkhead – FS 1016, LBL 15 [5] 8000/500 [3] 4000/500 [3] DET VISUAL 1.00
Fuselage Skin – FS 1040 Through FS 1088,
HY-3 8000/500 [3] 4000/500 [3] DET VISUAL 1.00
Stringer 17L Through 23L [5]
Fuselage Frames – FS 947.5 Through FS 1016,
HY-4 8000/500 [3] 4000/500 [3] DET VISUAL 1.00
Stringer 22L Through 23L [5]
Smoke Detectors Static Ports – Fuselage Skin [7]
SP-1 Fuselage Skin at FS 375, LBL 31.86 and WL 161.48 8000/500 [3] [8] 4000/500 [3] [8] DET VISUAL 1.00
SP-1 Fuselage Skin at FS 375, LBL 31.86 and WL 161.48 16000 [6] 16000 [6] HFEC @ Fastener 0.063
SP-1 Fuselage Skin at FS 375, LBL 31.86 and WL 161.48 8000 [6] 8000 [6] DET VISUAL 1.00
SP-2 Fuselage Skin at FS 727E +5, LBL 48.4 and WL 166.8 8000/500 [3] 4000/500 [3] DET VISUAL 1.00
Cargo Compartment
CC-1 [4] Emergency Exit Door Liner between FS 616 and FS 639 8000/500 [3] 4000/500 [3] DET VISUAL 1.00
CC-1 [4] Emergency Exit Door Liner between FS 616 and FS 639 8000/500 [3] 4000/500 [3] HFEC 0.063
CC-2 [4] Aft Pressure Bulkhead (FS 1016) I-Beams [1] 8000/500 [3] 8000/500 [3] DET VISUAL 1.00
CC-2 [4] Aft Pressure Bulkhead (FS 1016) I-Beams [1] 8000/500 [3] 8000/500 [3] HFEC 0.063
CC-3 [4] Aft Pressure Bulkhead (FS 1016) I-Beams [1] 8000/500 [3] 8000/500 [3] DET VISUAL 1.00
CC-3 [4] Aft Pressure Bulkhead (FS 1016) I-Beams [1] 8000/500 [3] 8000/500 [3] HFEC 0.063
CC-4 Sidewall Liner – Specified Frames [2] 8000/500 [3] 8000/500 [3] DET VISUAL 1.00
CC-4 Sidewall Liner – Specified Frames [2] 8000/500 [3] 8000/500 [3] HFEC 0.063
[1] CC-2 references the -79 install of the aft pressure bulkhead liner, and CC-3 references the -59 install of the aft pressure
bulkhead close-out panels. Inspections will be performed as indicated depending on whether the -59 or -79 installations are
installed. It is the responsibility of the inspector to determine the whether the CC-2 or CC-3 inspection is required.
[2] CC-4 (737-400 Full Freighter) differs from CC-5 (737-300 Full Freighter) in a few callouts for the isolators (WL dimension).
Inspections will be performed as indicated depending on which installation is installed. It is the responsibility of the inspector
to determine whether the CC-4 or CC-5 inspection is required. CC-6 is for the 737-400 Combination Freighter.
[3] Deleted.
[4] CC-1, CC-2, and CC-3 are for the full cargo version of the PEMCO modification and are only applicable to the 737-300 full
freighter conversion.
[5] HY-1 is for aircraft that have the hydraulic pump in the main landing gear wheel weel (modified after March 11, 2001). HY-
2, HY-3, and HY-4 are for aircraft that have the hydraulic pump aft of the aft pressure bulkhead (modified prior to March 11,
2001). If Service Bulletin 737-29-0011 has been performed (for aircraft modified prior to March 11, 2001), accomplish HY-1,
HY-2, HY-3, and HY-4.
[6] Aircraft that have been modified after March 11, 2001 have a different configuration and are subject to these inspections.
[7] 737-200/300 only.
[8] Aircraft that have been modified prior to March 11, 2001 have a different configuration and are subject to these inspections.
For aircraft already in service at the time of the issuance of Revision 12 of this document, inspections are to begin
within 4,000 flights, or before December 31, 2012, whichever occurs first.
05-30-10
Feb. 11, 2015
6.2.5 Cargo Door - Location
An overview of the cargo door location is given.
FWD
Figure 3: Cargo Door Modification
05-30-10
Feb. 11, 2015
6.2.6 Cargo Door Surround Structure - Location
An overview of the modification to the aircraft fuselage structure is given.
Figure 4: Cargo Door Surround Structure
05-30-10
Feb. 11, 2015
7. DETAILED INSPECTION FORMS
This section contains all the detailed inspection forms that are required to perform specialized inspections as part
of the normal maintenance of the aircraft.
7.1 Internal Structure – Visual Inspections

This section contains the inspection requirements for visual inspection of the interior of the aircraft fuselage.
05-30-10
Feb. 11, 2015
7.1.1 Internal Inspection, IN-1
INSPECTION INSTRUCTIONS REFERENCES ACCESS MANHOURS
MPD CPCP OTHERS INSP MHRS ELPSD
IN-1
TITLE: INTERNAL VISUAL INSPECTION [1] [2] [3] [4] [5] [6] [7]
[1] Boeing D6-38728, 737-300/400/500 Maintenance Planning Data

[2] PEMCO Report P03-113IM, “Basic Scheduled Maintenance Check, B737-300 Aircraft Modified By
PEMCO”
[3] Boeing D6-38728, 737-300/400/500 Maintenance Planning Data, Section 10
[4] PEMCO Report 2966, Supplemental Corrosion Prevention Control Program, Boeing 737-300/400,
Cargo Door Installation”
[5] Boeing D6-37089, “Boeing Supplemental Structural Inspection Document (SSID)”
[6] PEMCO Service Bulletin 737-52-0033
I. INSPECTION – IN-1
Surveillance Visual Inspections

For aircraft equipped with the 9G Bulkhead. From the interior of the aircraft, visually inspect the fuselage frames,
stringers, and skin and the floor beams from FS 344 to FS 360 at the 9G Bulkhead attachment locations (See [4]).
Inspections are to be performed from a distance not to exceed three (3) feet. Removal of interior panels, floor panels,
insulation blankets, etc…, is required to obtain access to structure.
For aircraft equipped with the 9G Net. From the interior of the aircraft, visually inspect the fuselage frames, stringer and
skin and the floor beams from FS 343 to FS 441 at the 9G Net attachment locations (See [4]). Inspections are to be
performed from a distance not to exceed three (3) feet. Removal of interior panels, floor panels, insulation blankets, etc…,
is required to obtain access to structure.
From the interior of the aircraft, visually inspect the fuselage frames, stringers, and skin between STR-5R & STR-25L and
fuselage stations FS 312 & FS 500B (See [4]). Inspections are to be performed from a distance not to exceed three (3)
feet. Removal of interior panels, insulation blankets, etc…, is required to obtain access to structure.
From the interior of the aircraft, in the area where antennas are installed (GPS (0340-53-0019), TCAS (0340-53-0016),
and ATC (0340-53-0050)), visually inspect the fuselage skin. Inspections are to be performed from a distance not to
exceed three (3) feet. Removal of interior panels, insulation blankets, etc…, is required to obtain access to structure.
The main cargo door is included in this inspection. Removal of interior panels, insulation blankets, etc…, is required to
obtain access to structure.
Detailed Visual Inspection

From the interior of the aircraft, visually inspect the fuselage frames, stringers, and skin between STR-2L & STR-4L and
fuselage stations FS 328 & FS 500B (See [4]). Inspections are to be performed from a distance not to exceed one (1) foot.
Removal of interior panels, insulation blankets, etc…, is required to obtain access to structure. The main cargo door
structure is included in this inspection.
From the interior of the aircraft, visually inspect the fuselage frames, stringers, and skin between STR-17L & STR-19L and
fuselage stations FS 328 & FS 500B (See [4]). Inspections are to be performed from a distance not to exceed one (1) foot.
Removal of interior panels, insulation blankets, etc…, is required to obtain access to structure. The main cargo door
structure is included in this inspection.
From the interior of the aircraft, in the area of the window belt doubler, visually inspect the main cargo door frames,
doublers, and skin between WL254 and WL238 and fuselage stations FS 360 & FS 500 (See [4]). Inspections are to be
performed from a distance not to exceed one (1) foot. Removal of interior panels, insulation blankets, etc…, is required to
obtain access to structure.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION IN-1
B737-200/300/400
DESCRIPTION: INTERNAL VISUAL INSPECTION OPERATOR: S/N:
Detail Visual Inspection
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CARD (NDT) No. FLIGHTS FLIGHTS
CYCLES
VISUAL INSPECTION - INTERIOR DET VISUAL 16000 16000
VISUAL INSPECTION – CARGO DOOR DET VISUAL 16000 16000
COMMENTS: ______________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
9G Barrier Fuselage
Attachment Points
9G Barrier Floor
Attachment Points
05-30-10
Feb. 11, 2015
IN-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
RESULTS:
STR
FS
(B/L)
REPORT POSITIVE CRACK INDICATION AT STR # (OR B/L) AND FS # AS APPROPRIATE
COMMENTS: ________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.1.2 Internal Structure, IN-2
IN-2
TITLE: TRANSVERSE FLOOR BEAMS [1] [2] [3] [4] [5] [6]
[9] [10] [7] [8]
[11] [12]
PEMCO”
[7] Jetaire Service Bulletin B737-26-8013, Inspection Details and Intervals
[8] Jetaire Instructions for Continued Airworthiness
[9] PEMCO Service Bulletin 737-57-0001, “57 – Fuselage – Inspection and Repair of Floor Beams In Wing
Area”, Revision 5
[10] PEMCO Service Bulletin 737-57-0002, “Wings – Center Wing Box – Longitudinal Floor Beam Inspection
and Repair Between Body Station 656 and Body Station 727B”, Revision 2
[11] PEMCO Service Bulletin 737-53-0026, “53 – Fuselage – Stub Beam Inspection/Repair”, Revision 1
From the interior of the aircraft, visually inspect the chords of modified floor beams from the forward end and aft sides
(See [4]). In the standard 8 Pallet configuration, transverse floor beams to be inspected span fuselage stations FS 344 to
FS 520 as well as FS 727B to FS 907. If a 9 Pallet configuration is used, floor beams to be inspected span fuselage
stations FS 344 to FS 520 as well as FS 727B to FS 1006. If the aircraft being inspected is a 737-400 Freighter-
Passenger Combi, there are no floor beam modifications aft of the main deck partition at FS 612. The inspection is to
span the floor beam from left hand side to right hand side of the aircraft and include inspection of the floor beam to frame
attachments.
737-300 and 400 aircraft that have been altered in accordance with PEMCO Supplemental Type Certificate (STC)
SA2968SO do not include modifications of the longitudinal floor beams between FS540 and FS727. The PEMCO
alteration for the 737-200/300/400 QC/F/Combi aircraft allows increased payload loading from the front spar (FS540) to
aft wheel well bulkhead (FS727). The area from FS540 to FS727B is to be inspected in accordance with D6-37089 and
D6-82669, with the exception of F-46, which requires a detailed visual inspection in place of a general visual inspection.
PEMCO Service Bulletins (SB’s) 737-57-0001, 737-57-0002, and 737-53-0026 were developed to address Airworthiness
Directives against the Boeing Type Design and reduce inspection thresholds and intervals of the Airworthiness Directives.
Visual inspections of the transverse floor beams are to be performed from a distance not to exceed three (3) feet.
Removal of floor panels, insulation blankets, etc…, is required to obtain access to structure.
737-400 aircraft that have been altered in accordance with Jetaire Supplemental Type Certificate (STC) ST00749LA-D
require inspections in accordance with Jetaire Instructions For Contiued Airworthiness (ICA) Document 9002C0013 Per
Jetaire Service Bulletin (SB) B737-26-8016. Installation of PEMCO STC SA2968SO alters the floor structure that has
been modified in accordance with ST00749LA-D, and those existing inspection requirements are altered as follows.
 Perform a detailed visual inspection of the attachment of the Jetaire fire suppressant system every 4,000 Flight
Cycles after the installation of the Pemco modification (or after rotary hole probe Inspection) in lieu of the Jetaire
inspection requirements. It is not required to continue to perform the Jetaire surface HFEC inspection of the floor
beam centered on the fastener head nor is it required to perform a rotary hole HFEC after the initial inspection.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: TRANSVERSE FLOOR BEAMS OPERATOR: S/N:
Section 43 Transverse Section 46 Transverse

Floor Beam Modification Floor Beam Modification
737-200/300/400 QC/F 737-200/300/400 QC/F
737-400 Combi
Main Deck Partition (FS 612)

Section 44/45 Over Wing And Pressure 737-400 Combi
Deck Longitudinal Floor Beams
737-200/300/400 QC/F
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
VISUAL INSPECTION – FLOOR BEAMS DET VISUAL 16000 16000
NDT – FLOOR BEAMS, ST00749LA-D NDT [1] [1]
Over Wing And Wheel Well Pressure Deck

[2] [2] [2]
– Longitudinal Floor Beams [2]
COMMENTS: _____________________________________________________________________
_B737-400 Freighter-Passenger Combi Floor Beams aft of Main Deck Partition are not modified and__
are to be inspected in accordance with existing maintenance documents._______________________
_________________________________________________________________________________
_[1] For B737-400 aircraft that have ST00749LA-D Installed, inspect in accordance with inspection___
notes given on page 32______________________________________________________________
_[2] For B737-200/300400 aircraft, inspect this area in accordance with Boeing D6-37089 and D6-___
82669 (except F-46), and PEMCO Service Bulletins 737-57-0001, 737-57-0002, and 737-53-0026.___
_________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
IN-2
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
DESCRIPTION: TRANSVERSE FLOOR BEAMS OPERATOR: S/N:
RESULTS:
B/L FS
REPORT POSITIVE CRACK INDICATION AT B/L # AND FS # AS APPROPRIATE
COMMENTS: ________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.1.3 Internal Structure, IN-3

IN-3
TITLE: COMBI MODIFICATIONS [1] [2] [3] [4] [5] [6] [7]

PEMCO”
Aircraft that are modified to the 737-400 Combi Passenger-Freighter configuration have additional structure when
compared to the typical Freighter or Quick Change configurations. This additional structure is included in this section.
There is a partition between the cargo compartment and the passenger compartment that is located at FS 612. From the
interior of the aircraft, inspect the partition attachments to the fuselage structure and the seat tracks. Visual inspections of
the partition attachments are to be performed from a distance not to exceed three (3) feet. Removal of the partition,
insulation blankets, liner, etc…, is required to obtain access to structure. Pay particular attention to the structure
attachments to the fuselage structure.
There is support structure for the Halon bottles in the aft end of the aircraft, located underneath the floor beams between
FS 927 and 847, and outboard of LBL 20. Visual inspections of the Halon support structure are to be performed from a
distance not to exceed three (3) feet. Removal of the cargo liner, etc…, is required to obtain access to structure. Pay
particular attention to the Halon support structure attachments to the fuselage frames and lower chord of the transverse
floor beams.
05-30-10
EFFECTIVITY: 737-400 Combi Page 35
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-400 Combi
DESCRIPTION: COMBI MODIFICATIONS OPERATOR: S/N:
Main Deck Partition (FS 612)

737-400 Combi Halon Bottle Installation (FS 827-947)
737-400 Combi
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
VISUAL INSPECTION – HALON
DET VISUAL 16000 16000
STRUCTURE
VISUAL INSPECTION – PARTITION DET VISUAL 16000 16000
COMMENTS: _____________________________________________________________________
PARTITION ATTACHMENT INSPECTION REQUIRES REMOVAL OF THE PARTITION___________
_________________________________________________________________________________
_________________________________________________________________________________
HALON SUPPORT STRUCTURE REQUIRES ACCESS THROUGH AFT LOWER CARGO HOLD___
DOOR____________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-400 Combi
Partition Fuselage
Attachment Points
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-400 Combi
Halon Support Frame

Attachment Points
View Looking Down
Halon Support Fuselage

Attachment Points
Typical View Looking Forward
05-30-10
Feb. 11, 2015
IN-3
JOB CARD B737-400 Combi
SHEET __1__ OF __2__
RESULTS:
STR FS STA BL FS STA
REPORT POSITIVE CRACK INDICATION AT STR # OR BL AND FS STA # AS APPROPRIATE
COMMENTS: ___________________________________________________________________
PARTITION ATTACHMENT INSPECTION REQUIRES REMOVAL OF THE PARTITION_________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
IN-3
SHEET __2__ OF __2__
View Looking Down
RESULTS:
STR FS STA BL FS STA
REPORT POSITIVE CRACK INDICATION AT STR # OR BL AND FS STA # AS APPROPRIATE
COMMENTS: ___________________________________________________________________
PAY PARTICULAR ATTENTION TO THE FUSELAGE ATTACHMENTS________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.2 External Structure – Visual Inspections
This section contains the inspection requirements for visual inspection of the exterior of the aircraft fuselage.
05-30-10
Feb. 11, 2015
7.2.1 External Structure, EX-1

EX-1
TITLE: EXTERNAL VISUAL INSPECTION [1] [2] [3] [4] [5] [6] [7]

PEMCO”
NOTE: Use inspection mirrors, bore scopes, lights, magnifying glasses, and other visual aides as required.
I. INSPECTION – EX-1
Surveillance Visual Inspection

For aircraft equipped with the 9G Bulkhead. From the exterior of the aircraft, visually inspect the external doubler and skin
from FS 344 to FS 360 at the 9G Bulkhead attachment locations (See [4]). Inspections are to be performed from a
distance not to exceed three (3) feet.
For aircraft equipped with the 9G Net. From the exterior of the aircraft, visually inspect the external doubler and skin from
FS 343 to FS 441 at the 9G Net attachment locations (See [4]). Inspections are to be performed from a distance not to
exceed three (3) feet.
From the exterior of the aircraft, visually inspect the external doubler and skin between STR-5R & STR-25L and fuselage
stations FS 312 & FS 500B (See [4]). Inspections are to be performed from a distance not to exceed three (3) feet. Pay
particular attention to the upper and lower main cargo door corner cutouts at fuselage stations 360 and 500.
Open the cargo door and, from exterior of the aircraft visually inspect the aircraft forward, upper, aft, and lower jamb
structure. Additionally visually inspect the forward, upper, aft, and lower edges of the cargo door. Removal of the interior
structure is not required for these inspections.
From the exterior of the aircraft, in the area where antennas are installed (GPS (0340-53-0019), TCAS (0340-53-0016),
and ATC (0340-53-0050)), visually inspect the main cargo door doubler. Inspections are to be performed from a distance
not to exceed three (3) feet. Antenna removal is not required.
The main cargo door is included in this inspection. Removal of the interior structure is not required for these inspections.

From the exterior of the aircraft, visually inspect the fuselage skin between STR-2L & STR-4L and fuselage stations FS
328 & FS 500B (See [4]). Inspections are to be performed from a distance not to exceed one (1) foot. The main cargo
door structure is included in this inspection.
From the exterior of the aircraft, visually inspect the fuselage skin between STR-17L & STR-19L and fuselage stations FS
328 & FS 500B (See [4]). Inspections are to be performed from a distance not to exceed one (1) foot. The main cargo
door structure is included in this inspection.
From the exterior of the aircraft, in the area of the window belt doubler, visually inspect the main cargo door skin between
WL254 and WL238 and fuselage stations FS 360 & FS 500 (See [4]). Inspections are to be performed from a distance not
to exceed one (1) foot.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION EX-1
B737-200/300/400
DESCRIPTION: EXTERNAL VISUAL INSPECTION OPERATOR: S/N:
Detail Visual Inspection
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
FS 312 TO FS 500B DET VISUAL 4000 4000
STR-5R TO STR-25L DET VISUAL 4000 4000
FS 344 TO FS 360, 9G BULKHEAD [1] DET VISUAL 4000 4000
FS 343 TO FS 411, 9G NET [1] DET VISUAL 4000 4000
COMMENTS: _MCD IS INCLUDED IN THIS INSPECTION___ _______________________________

__________________________________________________________________________________
____________[1] 9G NET OR 9G BULKHEAD INSTALLATION DETERMINED ON AIRCRAFT______
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION EX-1
B737-200/300/400
9G Barrier Fuselage
Attachment Points
9G Barrier Floor
Attachment Points
05-30-10
Feb. 11, 2015
EX-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
RESULTS:
STR FS STA STR FS STA
REPORT POSITIVE CRACK INDICATION AT STR # AND FS STA # AS APPROPRIATE
COMMENTS: MCD IS INCLUDED IN THIS INSPECTION _

___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.3 External Doubler
This section contains the inspection requirements for non-destructive inspection of the aircraft fuselage skin and
external doubler over the region where the external doubler is installed on the aircraft as part of the main cargo
door installation.
Most of these inspections (ED-1 through ED-8) are subsurface inspections of the fuselage skin, although alternate
inspections are allowed for surface and subsurface inspections from the aircraft interior of the fuselage skin.
Production changes were incorporated as part of 007-00120, Revision A that specified HFEC eddy current of
fastener holes prior to installation of the doubler. Aircraft delivered prior to December 31, 2005 do not incorporate
these production changes. Aircraft delivered after December 31, 2005 incorporate these production changes.
These production changes did not impact the area specified by ED-9. ED-9 is required for all aircraft
modifications.
Inspection ED-9 was added at Revision 12 of this document based on reported cracking in the external doubler at
the aft lower corner cutout of the main cargo door. Due to the similarity of the structure, ED-9 is applicable at all
four (4) corners of the door.
PEMCO Service Bulletin 737-52-0033 installs a new cargo door and support structure that is not subject to the
requirements of Airworthiness Directive 98-04-41. Aircraft that were modified after March 11, 2001 have a type
design that is similar to PEMCO Service Bulletin 737-53-0033 and are not subject to the requirements of
Airworthiness Directive 98-04-41.
Aircraft that have not incorporated Service Bulletin 737-52-0033 (installing a new main cargo door and fittings for
the upper jamb) or were not modified after March 11, 2001 are still subject to the requirements of AD 98-04-41.
ED-9 applies to all aircraft. ED-9 does not alleviate the requirements of AD 98-04-41.
05-30-10
Feb. 11, 2015
7.3.1 External Doubler Installation, ED-1

ED-1
TITLE: DOUBLER INSTALLATION UPPER [1] [2] [3] [4] [5] [6] [7]
JAMB @ STR 3R

PEMCO”
NOTE: Use Low Frequency Eddy Current procedure given in Appendix A for S-3R.
NOTE: Perform a detailed visual inspection of the specified NDT area prior to the required NDT inspections of that area.
Record and report any discrepancies before performing NDT inspections.
NOTE: Production changes were incorporated as part of 007-00120, Revision A that specified HFEC eddy current of
fastener holes prior to installation of the doubler. Aircraft delivered after December 31, 2005 incorporate these production
changes and are subject to a different inspection threshold than aircraft delivered prior to December 31, 2005 which do
not incorporate these production changes.
NOTE: Based on requests from operators, it is permissible to perform the inspection at the first fastener row from the
interior of the aircraft using the same information contained in Appendix A for S-3R. Further, it is permissible to perform
the inspection of the second fastener row from the interior of the aircraft using an HFEC fastener inspection. This
information is included in this section.
NOTE: For High Frequency Eddy Current Surface Inspections, reference Boeing 737 NDT Manual D6-37239
I. INSPECTION – ED-1
From the exterior of the aircraft, inspect the doubler rivets. This is an LFEC inspection of the PEMCO doubler rivets at
STA 312 to 500.38B, STR 3R, RIVETS, R1C1 – R1Ci, and RIVETS, R2C1 – R2Ci.
-ALTERNATE-
From the interior of the aircraft, inspect the doubler rivets. This is an LFEC inspection of the PEMCO doubler rivets at
STA 312 to 500.38B, STR 3R, RIVETS, R1C1 – R1Ci, and a HFEC surface inspection of RIVETS, R2C1 – R2Ci.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION ED-1
B737-200/300/400
DESCRIPTION: DOUBLER INSTALLATION UPPER JAMB OPERATOR: S/N:
@ STR 3R
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT FLIGHTS FLIGHTS
CARD (NDT) No.
CYCLES [2] [2]
RIVETS, R1C1-R1Ci LFEC [1] 8000 4000
RIVETS, R1C1-R1Ci ALTERNATE LFEC [3] 8000 4000
RIVETS, R2C1-R2Ci ALTERNATE HFEC [3] 8000 4000
COMMENTS: ________[1] USE S-3R LFEC PROCEDURE IN APPENDIX A – EXTERIOR____ _

________________________________________________________________________________
____________________[2]_Aircraft modified prior to December 31, 2005_____________________
________________________________________________________________________________
____________________[3] USE S-3R LFEC PROCEDURE IN APPENDIX A – INTERIOR, FIRST _
FASTENER ROW. SECOND FASTENER ROW, USE HFEC - INTERIOR_____________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
@ STR 3R
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [2] [2]
[3]
COMMENTS: ________[1] USE S-3R LFEC PROCEDURE IN APPENDIX A – EXTERIOR________

__________________________________________________________________________________
____________________[2]_Aircraft modified after December 31, 2005_________________________
__________________________________________________________________________________
____________________[3] USE S-3R LFEC PROCEDURE IN APPENDIX A – INTERIOR, FIRST _
FASTENER ROW. SECOND FASTENER ROW, USE HFEC - INTERIOR ______________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ED-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
@ STR 3R
RESULTS:
REPORT POSITIVE CRACK INDICATION AT ROW # AND COLUMN # AS APPROPRIATE
COMMENTS: _____ USE S-3R LFEC PROCEDURE IN APPENDIX A ________________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

ED-2
TITLE: DOUBLER INSTALLATION LOWER [1] [2] [3] [4] [5] [6] [7]
JAMB @ STR 23L

PEMCO”
NOTE: Use Low Frequency Eddy Current procedure given in Appendix A for S-23L.
interior of the aircraft using the same information contained in Appendix A for S-23L. Further, it is permissible to perform
STA 312 to 500.38B, STR 23L, RIVETS, R1C1 – R1Ci, and RIVETS, R2C1 – R2Ci.
-ALTERNATE-
STA 312 to 500.38B, STR 23L, RIVETS, R1C1 – R1Ci, and a HFEC surface inspection RIVETS, R2C1 – R2Ci.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: DOUBLER INSTALLATION LOWER JAMB OPERATOR: S/N:
@ STR 23L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [2] [2]
COMMENTS: __________[1] USE S-23L LFEC PROCEDURE IN APPENDIX A________________

__________________________________________________________________________________
______________________[2] For aircraft modified prior to December 31, 2005___________________
__________________________________________________________________________________
______________________[3] USE S-23L LFEC PROCEDURE IN APPENDIX A – INTERIOR, FIRST
FASTENER ROW. SECOND FASTENER ROW, USE HFEC – INTERIOR______________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
@ STR 23L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [2] [2]
COMMENTS: __________[1] USE S-23L LFEC PROCEDURE IN APPENDIX A________________

_________________________________________________________________________________
______________________[2] For aircraft modified after December 31, 2005___________________
__________________________________________________________________________________
______________________[3] USE S-23L LFEC PROCEDURE IN APPENDIX A – INTERIOR, FIRST
FASTENER ROW. SECOND FASTENER ROW, USE HFEC – INTERIOR_____________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ED-2
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
@ STR 23L
RESULTS:
COMMENTS: ________ USE S-23L LFEC PROCEDURE IN APPENDIX A _____________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

ED-3
TITLE: DOUBLER INSTALLATION AFT [1] [2] [3] [4] [5] [6] [7]
JAMB @ STATION 500B

PEMCO”
NOTE: Use the respective reference calibration coupons given for the following inspections.
STA 500B, STR 3R-14L, RIVETS, (A) – (B). This includes the rivets in the PEMCO doubler splice parts.
STA 500B, STR 14L-23L, RIVETS, (A) – (B). This includes the rivets in the PEMCO doubler splice parts.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: DOUBLER INSTALLATION AFT JAMB @ OPERATOR: S/N:
STATION 500B STR 3R-14L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [1] [1]
RIVETS, R1C1-RiC1 LFEC 29 16000 8000
COMMENTS: _____________[1] For aircraft modified prior to December 31, 2005______________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STATION 500B STR 3R-14L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [1] [1]
COMMENTS: _____________[1] For aircraft modified after December 31, 2005__________________

__________________________________________________________________________________
_______________________ __________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STATION 500B STR 14L-23L
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CARD (NDT) No. FLIGHTS
CYCLES
COMMENTS: _________________________________________________ ____________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ED-3
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
STATION 500B STR 3L-23L
RESULTS:
COMMENTS:____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.3.4 External Doubler Installation, ED-4 and ED-5

ED-4 and ED-5
TITLE: DOUBLER INSTALLATION FWD [1] [2] [3] [4] [5] [6] [7]
JAMB @ STATION 312
PEMCO”
STA 312, STR 3R – 7L, RIVETS (E) & (F).
II. INSPECTION – ED-5
STA 312, STR 18L – 23L (end of external doubler), RIVETS (A) & (B).
NOTE: Some aircraft have installed air stairs underneath the forward passenger entry door (approximately between STR
18L and 20L). If the aircraft have the air stairs installed, the external doubler will not extend over the air stair opening, and
the inspection at STA 312 between the lower jamb and upper jamb of the air stair door (approximately between STR 18L
and 20L) is not possible.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: DOUBLER INSTALLATION, FWD JAMB OPERATOR: S/N:
STA 312, STR 3R-7L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [1] [1]
RIVETS, E LFEC 29 16000 8000
RIVETS, F LFEC 2 16000 8000
COMMENTS: _____________[1] For aircraft modified prior to December 31, 2005________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STA 312, STR 3R-7L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [1] [1]
RIVETS, E LFEC 29 20000 8000
RIVETS, F LFEC 2 20000 8000
COMMENTS: _____________[1] For aircraft modified after December 31, 2005__________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STA 312, STR 3R-7L
05-30-10
Feb. 11, 2015
ED-4
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
STA 312, STR 3R-7L
RESULTS:
COLUMN COLUMN COLUMN COLUMN

ROW 1 2 ROW 1 2 ROW 1 2 ROW 1 2

COMMENTS: ____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________
INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STA 312, STR 18L-23L
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
RIVETS, A LFEC 31 32000 16000
RIVETS, B LFEC 6 32000 16000
COMMENTS: _________________________________________________ ____________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
05-30-10
Feb. 11, 2015
ED-5
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
RESULTS:
COLUMN COLUMN COLUMN COLUMN

ROW 1 2 ROW 1 2 ROW 1 2 ROW 1 2

COMMENTS: ____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________
INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

ED-6
TITLE: DOUBLER SPLICES STA 340 TO [1] [2] [3] [4] [5] [6] [7]
STA 476.25, STRINGER 3R

PEMCO”
NOTE: Use Low Frequency Eddy Current procedure given in Appendix B for S-3R.
interior of the aircraft using the same information contained in Appendix B for S-3R. Further, it is permissible to perform
STA 340, STA 384, STA 431.5, and STA 476.25, RIVETS, R1C1-R1C6 AND RIVETS, R2C1-R2C6.
-ALTERNATE-
STA 340, STA 384, STA 431.5, and STA 476.25, RIVETS, R1C1-R1C6 and an HFEC surface inspection of the PEMCO
doubler rivets at STA 340, STA 384, STA 431.5, and STA 476.25, RIVETS, R2C1-R2C6.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: DOUBLER SPLICES, STA 340.0 TO OPERATOR: S/N:
476.25, STR 3R
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [2] [2]
RIVETS, R1C1-R1C6 LFEC [1] 8000 4000
RIVETS, R2C1-R2C6 LFEC [1] 8000 4000
RIVETS, R1C1-R1C6 ALTERNATE LFEC [3] 8000 4000
RIVETS, R2C1-R2C6 ALTERNATE HFEC [3] 8000 4000
COMMENTS: __________[1] USE S-3R LFEC PROCEDURE GIVEN IN APPENDIX B____________

______________________[2] For aircraft modified prior to December 31, 2005__________________
__________________________________________________________________________________
______________________[3] USE S-3R LFEC PROCEDURE GIVEN IN APPENIX B – INTERIOR,___
FIRST FASTENER ROW. SECOND FASTENER ROW, USE HFEC - INTERIOR_________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
476.25, STR 3R
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [2] [2]
RIVETS, R1C1-R1C6 LFEC [1] 20000 4000
RIVETS, R2C1-R2C6 LFEC [1] 20000 4000
COMMENTS: ___________[1] USE S-3R LFEC PROCEDURE GIVEN IN APPENDIX B___________

_______________________[2] For aircraft modified after December 31, 2005___________________
__________________________________________________________________________________
_______________________[3] USE S-3R LFEC PROCEDURE GIVEN IN APPENDIX B –_________
INTERIOR, FIRST FASTENER ROW. SECOND FASTENER ROW, USE HFEC - INTERIOR_______
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ED-6
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
476.25, STR 3R
RESULTS:
COLUMN
FS ROW 1 2 3 4 5 6
1
2
1
2
COMMENTS: ________ USE S-3R LFEC PROCEDURE GIVEN IN APPENDIX B__________

_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

ED-7
TITLE: DOUBLER SPLICES [1] [2] [3] [4] [5] [6] [7]
STA 340 TO STA 476.25, STRINGER 23L

PEMCO”
NOTE: Use Low Frequency Eddy Current procedure given in Appendix B for S-23L.
interior of the aircraft using the same information contained in Appendix B for S-23L. Further, it is permissible to perform
From the exterior of the aircraft, inspect the doubler rivets. This is an LFEC inspection of the PEMCO Splice doubler
rivets at STA 340, STA 386.5, STA 431.5, and STA 473.5, RIVETS, R1C1-R1C6 AND RIVETS, R2C1-R2C6.
-ALTERNATE-
From the interior of the aircraft, inspect the doubler rivets. This is an LFEC inspection of the PEMCO Splice doubler rivets
at STA 340, STA 386.5, STA 431.5, and STA 473.5, RIVETS, R1C1-R1C6 and an HFEC surface inspection of the
PEMCO doubler rivets at STA 340, STA 386.5, STA 431.5, and STA 473.5, RIVETS, R2C1-R2C6.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: DOUBLER SPLICES FS 340 TO FS 473.5, OPERATOR: S/N:
STR 23L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [2] [2]
RIVETS, R1C1-R1C6 LFEC [1] 8000 4000
RIVETS, R2C1-R2C6 LFEC [1] 8000 4000
COMMENTS: ____________[1] USE S-23L LFEC PROCEDURE GIVEN IN APPENDIX B_________

________________________[2] For aircraft modified prior to December 31, 2005________________
__________________________________________________________________________________
________________________[3] USE S-23L LFEC PROCEDURE GIVEN IN APPENDIX B –________
INTERIOR, FIRST FASTENER ROW. SECOND FASTENER ROW, USE HFEC - INTERIOR_______
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STR 23L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [2] [2]
RIVETS, R1C1-R1C6 LFEC [1] 20000 4000
RIVETS, R2C1-R2C6 LFEC [1] 20000 4000
COMMENTS: ____________[1] USE S-23L LFEC PROCEDURE GIVEN IN APPENDIX B_________

__________________________________________________________________________________
________________________[2] For aircraft modified after December 31, 2005__________________
__________________________________________________________________________________
________________________[3] USE S-23L LFEC PROCEDURE GIVEN IN APPENDIX B –________
INTERIOR, FIRST FASTENER ROW. SECOND FASTENER ROW, USE HFEC – INTERIOR_______
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ED-7
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
STR 23L
RESULTS:
COLUMN
FS ROW 1 2 3 4 5 6
1
2
1
2
COMMENTS:_____ USE S-23L LFEC PROCEDURE GIVEN IN APPENDIX B____________

_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ED-8
TITLE: DOUBLER SPLICES, AFT JAMB FS [1] [2] [3] [4] [5] [6] [7]
500B

PEMCO”
rivets at STA 500B, STR 1 to 2L and STR 5L to 6L, RIVETS R1C1-R6C1 AND R1C2-R6C2.
rivets at STA 500B, STR 15L to 16L and STR 20L to 21L, RIVETS R1C1-R6C1 AND R1C2-R6C2.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: DOUBLER SPLICES, AFT JAMB FS 500B OPERATOR: S/N:
STR 1-2L & STR 5L-6L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [1] [1]
RIVETS, R1C1-R6C1 LFEC 12 16000 8000
RIVETS, R1C2-R6C2 LFEC 12 16000 8000
COMMENTS: _______________[1] For aircraft modified prior to December 31, 2005_____________

_________________________________________________________________ ________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STR 1-2L & STR 5L-6L
POST MOD NiT Ni

JOB METHOD COUPON
CARD (NDT) No.
CYCLES [1] [1]
RIVETS, R1C1-R6C1 LFEC 12 20000 8000
RIVETS, R1C2-R6C2 LFEC 12 20000 8000
COMMENTS: ______________[1] For aircraft modified after December 31, 2005________________

_______________________________________________________________ __________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
STR 15L-16L & STR 20L- 21L
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
RIVETS, R1C1-R6C1 LFEC 12 32000 16000
RIVETS, R1C2-R6C2 LFEC 12 32000 16000
COMMENTS: _________________________________________________ ____________________

__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ED-8
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
DESCRIPTION: DOUBLER SPLICES, AFT JAMB FS OPERATOR: S/N:
500B STR 15L-16L & STR 20L – 21L
RESULTS:
ROW
STR COLUMN 1 2 3 4 5 6
1
2
1
2
COMMENTS:____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

ED-9
TITLE: MAIN CARGO DOOR DOUBLER – [1] [2] [3] [4] [5] [6] [7]
CORNERS OF DOOR FUSELAGE OPENING

PEMCO”
This is an inspection of the cargo door external doubler. This inspection is based on collected service data that indicates
cracking has occurred in the lower aft door corner. Due to similarity of the structure, all four (4) corners will be inspected
at the same intervals.
From the exterior of the aircraft, inspect the external doubler. This is a general surface HFEC inspection of the external
doubler in the areas specified as follows, and includes an HFEC inspection of the external doubler centered on the
existing fastener heads.
Forward Upper Corner: between FS 350 and FS 370, and between S-3L and S-4L
Aft Upper Corner: between FS 490 and FS 510, and between S-3L and S-4L
Forward Lower Corner: between FS 350 and FS 370, and between S-17L and S-18L
Aft Lower Corner: between FS 490 and FS 510, and between S-17L and S-18L
NOTE: Hinge removal at the upper forward and aft corners is not required.
NOTE: Fairing removal at upper forward and aft corners is required.
NOTE: Partial scuff plate removal is required to gain access for the lower forward and aft corners.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
MAIN CARGO DOOR DOUBLER – CORNERS OF DOOR
FUSELAGE OPENING
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
FS 350- 370 & FS490-510, DETAILED
2000 2000
BETWEEN S-3L TO S-4L VISUAL
FS 350- 370 & FS490-510, DETAILED
2000 2000
BETWEEN S-17L TO S-18L VISUAL
FS 350- 370 & FS490-510,

HFEC 8000 4000
BETWEEN S-3L TO S-4L
FS 350- 370 & FS490-510,
HFEC 8000 4000
BETWEEN S-17L TO S-18L
COMMENTS: DETAILED VISUAL INSPECTION OF EXTERIOR FASTENERS AT MAIN CARGO DOOR
OPENING BETWEEN FS 350- 370 & FS490-510, BETWEEN S-3L TO S-4L, AND FS 350- 370 & FS490-510,
BETWEEN S-17L TO S-18L __
HFEC INSPECTION OF CARGO DOOR CORNER AREAS AS DEFINED ON SHT 2 OF 2 OF ED-9. FAIRING
REMOVAL REQUIRED AT UPPER CORNERS. SCUFF PLATE REMOVAL REQUIRED AT LOWER _
CORNERS____ _
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION:: OPERATOR: S/N:
FUSELAGE OPENING
FS 350 FS 370 FS 490 FS 510
S-3L
S-4L
External HFEC Inspections
S-17L
S-18L
Typical Section Inspection
Stringer Stringer
HFEC of External
External Visual Doubler
Stringer Stringer
Exterior Interior Exterior Interior
05-30-10
Feb. 11, 2015
ED-9
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
FUSELAGE OPENING
RESULTS:
WL FS STA WL FS STA
REPORT POSITIVE CRACK INDICATION AT STA # AND WL # AS APPROPRIATE
COMMENTS: _______________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.4 Cargo Door
This section contains the inspection requirements for non-destructive inspection of the main cargo door.
These inspections (CD-1 through CD-4) are inspections of the cargo door skin and cargo door fittings at the
locations where load transfer from the cargo door to the upper or lower jamb occurs.
PEMCO Service Bulletin 737-52-0033 installs a new cargo door and support structure that is not subject to the
requirements of Airworthiness Directives 98-04-41 and 2004-03-23. Aircraft that were modified after March 11,
2001 have a type design that is similar to PEMCO Service Bulletin 737-52-0033 and are not subject to the
requirements of Airworthiness Directives 98-04-41 and 2004-03-23.
Aircraft that have not incorporated Service Bulletin 737-52-0033 (installing a new main cargo door and fittings for
the upper jamb) or were not modified after March 11, 2001 are still subject to the requirements of Airworthiness
Directives 98-04-41 and 2004-03-23.
The detailed inspection forms shown for CD-1 through CD-4 only apply to aircraft that have installed PEMCO
Service Bulletin 737-52-0033 or were modified after March 11, 2001. Aircraft that have not installed PEMCO
Service Bulletin 737-52-0033 or were not modified after March 11, 2001 do not have the structure specified by
CD-1 through CD-4 and are subject to the requirements of Airworthiness Directives 98-04-41 and 2004-03-23.
Some configurations that have installed PEMCO Service Bulletin 737-52-0033 or were modified after March 11,
2001 have a doubler installation while other configurations do not have a doubler installed as part of the actuator
fitting installation (CD-1 and CD-2). For both of these configurations, perform both the detailed visual inspection
and the high frequency eddy current as specified by inspections given for CD-1 and CD-2. Removal of doubler
required only if doubler is installed.
For the configurations that have not installed PEMCO Service Bulletin 737-52-0033 or were modified before
March 11, 2001, perform the following inspections in addition to the inspections specified by Airworthiness
Directive 98-04-41.
o Perform a detailed visual inspection of the cargo door structure, from the aircraft interior at a threshold of
8,000 flights, repeating every 8,000 flights thereafter from FS 373 to FS 379 and WL 287.5 to WL 298.0
and FS 482 to FS 488, WL 287.5 to WL 298.0.
o Perform a high frequency rotary hole inspection of the cargo door structure, after fastener removal, from
the aircraft interior at a threshold of 32,000 flights, repeating every 32,000 flights thereafter from FS 373
to FS 379, WL 287.5 to WL 298.0 and FS 482 to FS 488, WL 287.5 to WL 298.0.
o For guidance, reference CD-1 and CD-2.
05-30-10
Feb. 11, 2015
7.4.1 Cargo Door Installation, CD-1 Through CD-4

CD-1 TO CD-4
TITLE: MAIN CARGO DOOR SKIN, [1] [2] [3] [4] [5] [6] [7]
ACTUATOR FITTINGS AND UPPER
FITTINGS

PEMCO”
NOTE: For High Frequency Eddy Current Surface Inspections and Rotary High Frequency Bolt Hole Inspections,
reference Boeing 737 NDT Manual D6-37239
I. INSPECTION – CD-1 [1]
From the interior of the cargo door, inspect the MCD skin and forward actuator fitting. This is a Visual inspection of the
outer skin and the actuator fittings from FS 373 to FS 379 and 16 fasteners WL 298-285.70 that is to be performed from a
distance not to exceed one (1) foot. This inspection also includes an HFEC inspection of the Actuator Fitting fastener
holes.
II. INSPECTION – CD-2 [1]
From the interior of the cargo door, inspect the MCD skin and aft actuator fitting. This is a Visual inspection of the outer
skin and the actuator fittings from FS 482 to FS 488 and 16 fasteners WL 298-285.70 that is to be performed from a
distance not to exceed one (1) foot. This inspection also includes an HFEC inspection of Actuator Fitting fastener holes.
III. INSPECTION – CD-3
From the interior of the cargo door, inspect the MCD Upper Fittings. This is an HFEC inspection of the upper fitting at 16
fastener holes common to the frames and the fittings requiring fastener removal. This inspection includes 4 fastener holes
at 4 locations. It also requires a detailed visual inspection of the fittings.
IV. INSPECTION – CD-4
From the interior of the cargo door, inspect the MCD Upper Latch fastener holes. This is an HFEC inspection of the latch
at a total of 32 fastener holes common to the frames and the fittings. This inspection includes 4 fasteners at 8 locations.
[1] Aircraft subject to the requirements of AD 98-04-41 are also subject to additional inspections similar to those specified by CD-1 and
CD-2. On aircraft subject to the requirements of AD98-04-41, no actuator fitting exists. It is required to perform the detailed visual
inspections called out by CD-1 and CD-2 in the zone specified. It is also required to remove the fasteners and perform an HFEC
inspection of the fastener holes in the zone specified (where the Actuator Fitting is located on the new type design, installed
PEMCO Service Bulletin 737-52-0033 or were modified after March 11, 2001).
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION CD-1
B737-200/300/400
DESCRIPTION: MCD SKIN AND FORWARD ACTUATOR OPERATOR: S/N:
FITTING
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
ACTUATOR FITTING, FS 373
TO FS 379, 16 FASTENERS VISUAL 8000 8000
WL 298 TO 285.70
ACTUATOR FITTING
SURFACE [1]
ACTUATOR FITTING
HFEC 32000 32000
FASTENER HOLES [2]
CARGO DOOR FASTENER

HOLES FS 373 TO FS 379, WL HFEC 32000 32000
298 TO 285.70 [3]
COMMENTS: ___[1] REMOVE DBLR (IF INSTALLED) AND PERFORM A SURFACE DETAILED____
________________ VISUAL INSPECTION OF ACTUATOR FITTING_________________________
_________________________________________________________________________________
_______________[2] REMOVE FASTENERS AND INSPECT HOLES WITH HFEC PROBE_________
_________________________________________________________________________________
_______________[3] AIRCRAFT SUBJECT TO AD 98-04-01 ONLY___________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
CD-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
DESCRIPTION: MCD SKIN AND FORWARD ACTUATOR OPERATOR: S/N:
FITTING
RESULTS:
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
REPORT POSITIVE CRACK INDICATION AT FASTENER NUMBER AS APPROPRIATE
COMMENTS: REMOVE DBLR (IF INSTALLED) AND PERFORM A SURFACE DETAILED_____

_______________ VISUAL INSPECTION OF ACTUATOR FITTING __________________________
_________________________________________________________________________________
_______________REMOVE FASTENERS AND INSPECT HOLES WITH HFEC PROBE _
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: MCD SKIN AND AFT ACTUATOR FITTING OPERATOR: S/N:
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
ACTUATOR FITTING, FS 482
TO FS 488, 16 FASTENERS VISUAL 8000 8000
U/L 298-285.70
ACTUATOR FITTING
SURFACE [1]
ACTUATOR FITTING
HFEC 32000 32000
FASTENER HOLES [2]
CARGO DOOR FASTENER

HOLES FS 482 TO FS 488, WL HFEC 32000 32000
298 TO 285.70 [3]
COMMENTS: ___[1] REMOVE DBLR (IF INSTALLED) AND PERFORM A SURFACE DETAILED____
________________ VISUAL INSPECTION OF ACTUATOR FITTING_________________________
_________________________________________________________________________________
_______________[2] REMOVE FASTENERS AND INSPECT HOLES WITH HFEC PROBE________
_________________________________________________________________________________
_______________[3] AIRCRAFT SUBJECT TO AD 98-04-01 ONLY___________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
CD-2
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
DESCRIPTION: MCD SKIN AND AFT ACTUATOR FITTING OPERATOR: S/N:
RESULTS:
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
REPORT POSITIVE CRACK INDICATION AT FASTENER NUMBER AS APPROPRIATE
COMMENTS: REMOVE DBLR (IF INSTALLED) AND PERFORM A SURFACE DETAILED_____

_______________ VISUAL INSPECTION OF ACTUATOR FITTING __________________________
_________________________________________________________________________________
_______________REMOVE FASTENERS AND INSPECT HOLES WITH HFEC PROBE _
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-
FORM SHEET __1__ OF __2__ 200/300/400
DESCRIPTION: MCD UPPER FITTING OPERATOR: S/N:
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
MCD UPPER FITTING [1] HFEC 32000 32000
MCD UPPER FITTING [2] DET VISUAL 16000 16000
COMMENTS: _[1] REMOVE FASTENERS COMMON TO HINGE, HINGE SHIM, FRAME AND SHIM_
INSPECT HOLES WITH HFEC PROBE. 4 FASTENERS AT 4 LOCATIONS, TOTAL 16 _
FASTENERS._______________________________________________________________________
_____________[2] DETAILED VISUAL INSPECTION OF FITTINGS, NO FASTENER REMOVAL____
REQUIRED.________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
05-30-10
Feb. 11, 2015
CD-3
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
RESULTS:
FS 1 2 3 4
460
440
420
400
REPORT POSITIVE CRACK INDICATION AT FS & FASTENER # AS APPROPRIATE

COMMENTS: ____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: MCD LATCH ASSEMBLY FASTENERS OPERATOR: S/N:
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
UPPER LATCH FASTENER HOLES HFEC 32000 32000
COMMENTS: _REMOVE UPPER FASTENERS COMMON TO DOOR LATCH FITTING, FRAME___

_____________AND BATHTUB FITTINGS.______________________________________________
_____________INSPECT HOLES WITH HFEC PROBE. 4 PER FRAME (32 TOTAL)____________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
05-30-10
Feb. 11, 2015
CD-4
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
RESULTS:
FS 1 2 3 4 FS 1 2 3 4
490.8 420
480 400
460 380
440 369.21
REPORT POSITIVE CRACK INDICATION AT FS AND FASTENER # AS APPROPRIATE
COMMENTS: _REMOVE UPPER FASTENERS COMMON TO DOOR LATCH FITTING, FRAME___

_____________AND BATHTUB FITTINGS.______________________________________________
_____________INSPECT HOLES WITH HFEC PROBE. 4 PER FRAME (32 TOTAL)____________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.5 Upper Jamb
This section contains the inspection requirements for non-destructive inspection of the upper jamb structure that
is part of the main cargo door surround structure, and transfers load from the door to the upper fuselage structure.
05-30-10
Feb. 11, 2015
7.5.1 Upper Jamb Installation, UJ-1

UJ-1
TITLE: UPPER JAMB @ STR 2L [1] [2] [3] [4] [5] [6] [7]

PEMCO”
NOTE: Based on requests from operators, it is permissible to perform the inspection of the fasteners using a HFEC rotary
bolt hole inspection after fastener removal. This information is included in this section.
reference Boeing 737 NDT Manual D6-37239
I. INSPECTION – UJ-1
From the interior of the aircraft, inspect the frame fasteners at the PEMCO to Boeing frame segment, lower clip. This is an
HFEC inspection of the PEMCO LOWER CLIP, FILLET RADIUS at STR 2L and FS 370, FS 380, FS 400, FS 420, FS
440, FS 460, FS 480, or FS 490. This is also an LFEC inspection of the LOWER CLIP BASE FASTENERS at STR 2L and
FS 370, FS 380, FS 400, FS 420, FS 440, FS 460, FS 480, or FS 490.
-ALTERNATE-
From the interior of the aircraft, inspect the frame fasteners at the PEMCO to Boeing frame segment, lower clip. This is an
HFEC inspection of the PEMCO LOWER CLIP, FILLET RADIUS at STR 2L and FS 370, FS 380, FS 400, FS 420, FS
440, FS 460, FS 480, or FS 490. This is also an HFEC rotary bolt hole inspection of the LOWER CLIP BASE
FASTENERS at STR 2L and FS 370, FS 380, FS 400, FS 420, FS 440, FS 460, FS 480, or FS 490 after fastener
removal.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION UJ-1
B737-200/300/400
DESCRIPTION: UPPER JAMB - FRAME SEGMENT OPERATOR: S/N:
CLIP (LOWER) @ STRINGER 2L
POST NiT Ni
STRUCTURE 1 JOB METHOD COUPON MOD
CARD (NDT) No. FLIGHT FLIGHTS FLIGHTS
CYCLES
CLIP (LOWER) – FILLET
HFEC NA 4000 4000
RADIUS
CLIP (LOWER) – BASE
LFEC 25 4000 4000
FASTENERS

FASTENERS ALTERNATE HFEC
2 NA 4000 4000
COMMENTS: ____ONLY
1 REQUIRED ON AIRCRAFT THAT WERE MODIFIED PRIOR TO ________
________________MARCH 11, 2001 AND HAVE NOT INCORPORATED SB 737-52-0033_________
________________This
2 is an alternate inspection that requires removal of all fasteners from clip. A _
________________rotary bolt hole inspection is performed on the fastener holes. ____________ _
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
S-2L
B-B
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
POST MOD NiT Ni

STRUCTURE 1 JOB METHOD COUPON
FLIGHT
CYCLES
CLIP (LOWER) – FILLET RADIUS HFEC NA 4000 4000

HFEC NA 4000 4000
FASTENERS
2
COMMENTS: ____ONLY
1 REQUIRED ON AIRCRAFT THAT WERE MODIFIED PRIOR TO ________
________________MARCH 11, 2001 AND HAVE NOT INCORPORATED SB 737-52-0033_________
__________________________________________________________________________________
_________________This
2 is an alternate inspection that requires removal of all fasteners___________
__________________from clip. A rotary bolt hole inspection is performed on the fastener holes. _
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
UJ-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
RESULTS:
FS 1 2 3 4 SURF FS 1 2 3 4 SURF
370 440
380 460
400 470
420 480
REPORT POSITIVE CRACK INDICATION AT FS AND FASTENER # OR SURFACE AS

APPROPRIATE
COMMENTS: 1 ONLY REQUIRED ON AIRCRAFT THAT WERE MODIFIED PRIOR TO _
MARCH 11, 2001 AND HAVE NOT INCORPORATED SB 737-52-0033________
2 An HFEC rotary bolt hole probe may be performed in lieu of the LFEC at the _
_ indicated fasteners. Indicate inspection performed. _
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

UJ-2
TITLE: UPPER JAMB @ STR 1, 2R, 4R, [1] [2] [3] [4] [5] [6] [7]
5R

PEMCO”
NOTE: For Rotary High Frequency Bolt Hole Inspections, reference Boeing 737 NDT Manual D6-37239
From the interior of the aircraft, inspect the Boeing frame at the first four (4) frame fasteners at the termination of the
PEMCO structure. This is a general surface HFEC inspection of the Boeing web centered on the fasteners that are
common to the PEMCO structure and the Boeing frame at the PEMCO frame termination area. Reference Boeing NDT
Part 6 Ch 51-00-00. Do not remove fasteners or parts unless required. If fasteners removed, reinstall same type and size
per Boeing SRM.
BS312, BS328: Inspect at last four fastener heads common to Boeing frame. Remove fasteners common to the 007-
00415-3 and perform rotary hole inspection at two (2) locations, perform frame web inspection at two (2) locations.
Production variation may require inspecting last five (5) fastener locations.
BS344: Inspect at last four fastener heads common to Boeing frame and 007-00234-1 just above S-5R. Remove
fasteners common to fail-safe chord and perform rotary hole inspection at two (2) locations, perform frame web inspection
at two (2) locations.
BS360: Inspect frame web at last four fastener heads common to Boeing frame and 007-0214-1 just below S-4R.
BS380, BS480: Inspect frame web at last four fastener heads common to Boeing frame and 007-00406-43 just above S-
6R.
BS400 thru BS460: Inspect frame web at last four fastener heads common to Boeing frame and 007-00406-43 just above
S-6R.
BS500, BS500A: Inspect at last four fastener heads common to Boeing frame and 007-00310-1 just below S-5R.
If a production variation of the PEMCO structure installed at FS344 through FS500B is such that the Boeing frame web
inspection specified by UJ-2 can not be performed due to an existing structure installation, remove the fastener common
to the structure, PEMCO frame, and Boeing frame and perform a Rotary High Frequency Bolt Hole Inspection. If no
cracks detected, reinstall fastener in accordance with Boeing SRM.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
PEMCO/BOEING WEB SPLICE
Approximate Inspection Locations
FS380, S-5½R FS420, S-5½R FS460, S-5½R FS500, S-5½R
FS344, S-4½R
FS400, S-5½R FS440, S-5½R FS480, S-5½R FS500A, S-5½R

FS360, S-4½R
FS312, S-1 FS500B, S-1
FS328, S-1
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
BOEING WEB SPLICE – WEB
HFEC N/A 8000 8000
FASTENERS
COMMENTS: _FIRST 4 FASTENERS COMMON TO BOEING FRAME AND PEMCO FRAME ARE__
TO BE INSPECTED. FASTENER REMOVAL REQUIRED AT STRINGER 1 STRINGER TIE FOR____
FS312 AND FS328. PRODUCTION VARIATION MAY REQUIRE INSPECTION OF FIRST 5________
FASTENERS COMMON TO BOEING FRAME AND PEMCO FRAME. FASTENER REMOVAL______
REQUIRED AT FS344 AT FAIL SAFE CHORD IN TWO (2) LOCATIONS. _____________
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
FS500B Shown, No Fastener

Removal Required
FS312 And FS328 Shown,

Shown, Fastener Removal
Required At Stringer Attachment
Fastener Removal At
Stringer Required (FS312
& FS328 Only)
Fastener Removal At
Stringer Required (FS312
& FS328)
Typical Installation At FS312 & Production Variation At FS312

FS328 Shown. FS500B Similar. And FS328 Shown
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
Typical Installation (FS380, FS400,

FS420, FS440, FS460, & FS480)
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
Typical Installation (FS344)
Fastener Removal At Fail

Safe Chord Required
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
Typical Installation (FS360,

FS500, & FS500A)
05-30-10
Feb. 11, 2015
UJ-2
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
TYPICAL REFERENCE VIEW
RESULTS:
FS 1 2 3 4 FS 1 2 3 4

COMMENTS: ___ FIRST 4 FASTENERS COMMON TO BOEING FRAME AND PEMCO_______
____________ FRAME ARE TO BE INSPECTED EXCEPT AS NOTED BY PRODUCTION_____
________________VARIATIONS________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

UJ-3
TITLE: UPPER JAMB FITTINGS @ [1] [2] [3] [4] [5] [6] [7]
STRINGER 3L

PEMCO”
NOTE: For Rotary High Frequency Bolt Hole Inspections, reference Boeing 737 NDT Manual D6-37239
From the interior of the aircraft, inspect the Upper Frame Fittings at the PEMCO to Boeing Frame. This is an HFEC
inspection of the PEMCO Upper Jamb Fitting Base, Pad Fastener Holes (LFEC), Web (Ribs), Base fastener Holes, @
STR 3L and FS 370, FS 380, FS 400, FS 420, FS 440, FS 460, FS 480, and FS 490.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: UPPER JAMB FITTINGS OPERATOR: S/N:
@ STRINGER 3L
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
DETAILED
UJ FITTING N/A 16000 16000
VUSUAL
UJ FITTING – FASTENER HOLES
HFEC 32000 32000
(PAD)
1
1
COMMENTS: ____FASTENER REMOVAL REQUIRED____________________________ ________
________________4 FASTENERS @ FS 370, 380, 480, 490_________________________________
________________6 FASTENERS @ FS 400, 420, 440, 460_________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
@ STRINGER 3L
05-30-10
Feb. 11, 2015
UJ-3
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
@ STRINGER 3L
RESULTS:
FS 1 2 3 4 FS 1 2 3 4 5 6
370 400
380 420
480 440
490 460

COMMENTS: FASTENER REMOVAL REQUIRED _
_ 4 FASTENERS @ FS 370, 380, 480, 490_________________________________
_ 6 FASTENERS @ FS 400, 420, 440, 460 _
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.6 Lower Jamb
This section contains the inspection requirements for non-destructive inspection of the lower jamb structure that is
part of the main cargo door surround structure, and transfers load from the door to the lower fuselage structure.
05-30-10
Feb. 11, 2015
7.6.1 Lower Jamb Installation, LJ-1

LJ-1
TITLE: LOWER JAMB BLADE FITTINGS [1] [2] [3] [4] [5] [6] [7]
FROM FS 369.21 TO FS 490.8 [8]

PEMCO”
[7] These inspections are per the requirements of AD 2001-09-05 which mandated the incorporation of
service bulletin 737-53-003. Production after March 11, 2001 inspection requirements are those
given for LJ-1A.
NOTE: The views shown for LJ-1 are representative and may not match aircraft configuration exactly.
NOTE: For Rotary High Frequency Bolt Hole Inspections, reference Boeing 737 NDT Manual D6-37239.
I. INSPECTION – LJ-1
This is an HFEC inspection of the fastener holes common to the 007-00528 Blade Fitting and PEMCO Frames at FS369,
FS380, FS400, FS420, FS440, FS460, FS480, and FS491. Fastener removal is required. The nine (9) fasteners
common to the PEMCO frames and 007-00528 Blade Fittings are to be removed and the fastener holes are to be
inspected using HFEC bolt-hole probes.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION LJ-1
B737-200/300/400
DESCRIPTION: PEMCO LOWER JAMB BLADE OPERATOR: S/N:
FITTINGS FROM FS 369.21 TO FS 490.8
STRUCTURE NiT Ni
POST MOD
JOB METHOD COUPON
FLIGHT
CYCLES
FASTENER HOLES HFEC N/A 0 8000

1
1
COMMENTS: ____AIRCRAFT MODIFIED AFTER MARCH 11, 2001 ARE NOT SUBJECT TO THESE
________________INSPECTIONS. THESE INSPECTIONS ARE FOR AIRCRAFT THAT HAVE____
________________INCORPORATED PEMCO SB 737-53-0003 AS AN AMOC TO AD 2001-090-05._
________________FIRST INSPECTION OCCURS PRIOR TO INTALL OF SB 737-53-0003________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESRCIPTION: PEMCO LOWER JAMB BLADE OPERATOR: S/N:
05-30-10
Feb. 11, 2015
LJ-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
DESRCIPTION: PEMCO LOWER JAMB BLADE OPERATOR: S/N:
RESULTS:
FS 1 2 3 4 5 6 7 8 9

COMMENTS: AIRCRAFT MODIFIED AFTER MARCH 11, 2001 ARE NOT SUBJECT TO THESE__
_____________INSPECTIONS. THESE INSPECTIONS ARE FOR AIRCRAFT THAT HAVE______
INCORPORATED PEMCO SB 737-53-0003 AS AN AMOC TO AD 2001-090-05.___
______________FIRST INSPECTION OCCURS PRIOR TO INTALL OF SB 737-53-0003__________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.6.2 Lower Jamb Installation, LJ-1A

LJ-1A
TITLE: PEMCO LOWER JAMB BLADE [1] [2] [3] [4] [5] [6] [7]
FITTINGS FROM FS 369.21 TO FS 490.8 [8]

PEMCO”
[7] These inspections are per the requirements of AD 2001-09-05 which mandated the incorporation of
service bulletin 737-53-003. Production prior to March 11, 2001 inspection requirements are those
given for LJ-1.
NOTE: The views shown for LJ-1A are representative and may not match aircraft configuration exactly.
NOTE: For Rotary High Frequency Bolt Hole Inspections, reference Boeing 737 NDT Manual D6-37239.
I. INSPECTION – LJ-1A
This is an HFEC inspection of the fastener holes common to the 007-00528 Blade Fitting and PEMCO Frames at FS369,
FS380, FS400, FS420, FS440, FS460, FS480, and FS491. Fastener removal is required. The twelve (12) fasteners
common to the PEMCO frames and 007-00528 Blade Fittings are to be removed and the fastener holes are to be
inspected using HFEC bolt-hole probes.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION LJ-1A
B737-200/300/400
DESCRIPTION: PEMCO LOWER JAMB BLADE FITTINGS OPERATOR: S/N:
FROM FS 369.21 TO FS 490.8
STRUCTURE NiT Ni
POST MOD
JOB METHOD COUPON
FLIGHT
CYCLES
FASTENER HOLES HFEC N/A 32000 16000

1
COMMENTS: ____AIRCRAFT
1 MODIFIED AFTER MARCH 11, 2001 ARE SUBJECT TO THESE
________________INSPECTIONS. ___________________________________________________
__________________________________________________________________________________
_________________________________________________________________________ ________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION LJ-1A
B737-200/300/400
FROM FS 369.21 TO FS 490.8
05-30-10
Feb. 11, 2015
LJ-1A
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
FROM FS 369.21 TO FS 490.8
RESULTS:
FASTENER #
FS

COMMENTS: AIRCRAFT MODIFIED AFTER MARCH 11, 2001 ARE SUBJECT TO THESE _
INSPECTIONS. _
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.6.3 Lower Jamb Installation, LJ-2

LJ-2
TITLE: PEMCO LOWER JAMB FITTING [1] [2] [3] [4] [5] [6] [7]
FASTENERS @ FS 369.21, FS 380, FS
400, FS 420, FS 440, FS 460, AND FS
490.8
PEMCO”
NOTE: The views shown for LJ-2 are representative and may not match aircraft configuration exactly.
NOTE: For High Frequency Eddy Current Surface Inspections, reference Boeing 737 NDT Manual D6-37239.
I. INSPECTION – LJ-2
This is an HFEC inspection of the inboard fasteners common to the 007-00519 Latch Fitting and the 007-00528 Blade
Fitting at FS369, FS380, FS400, FS420, FS440, FS460, FS480, and FS491. The two (2) inboard fasteners common to
the 007-00519 and the 007-00528 fasteners are to be removed and inspected.
In lieu of fastener inspection, it is acceptable to remove and replace the indicated bolts with the same bolt type provided
acceptance criteria of the originally installed bolts is used. If replacement bolts are used, they are to be installed using
installation drawing torque values and not standard torque values. If fastener replacement is chosen, contact PEMCO
(see section 2.1, page 13) for installation instructions.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: PEMCO LOWER JAMB FITTING OPERATOR: S/N:
FASTENERS @ FS 369.21, FS 380, FS 400, FS 420,
FS 440, FS 460, AND FS 490.8
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
FASTENER HFEC N/A 32000 32000
BACB30US-6 (2)
COMMENTS: 2 PER LOCATION, 16 FASTENERS TO BE REMOVED AND INSPECTED TYPICAL__

___________VIEW SHOWN IN VIEW A-A. FASTENER INSPECTION APPLICABLE TO FS 369.21,_
___________380, 400, 420, 440, 460, 470, 480, 490.8.__FASTENER REMOVAL AND____________
___________REPLACEMENT USING DWG TORQUE AND FASTENERS IS ACCEPTABLE________
__________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
FS 440, FS 460, AND FS 490.8
STRUCTURE NiT Ni
POST MOD
JOB METHOD COUPON
FLIGHT
CYCLES
FASTENERS (2) 1 HFEC 32000 32000
1
COMMENTS: ____REMOVE & REPLACE IS ACCEPTABLE________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
LJ-2
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
FS 440, FS 460, AND FS 490.8
RESULTS:
FASTENER # FASTENER #
FS 1 2 FS 1 2
369 440
380 460
400 480
420 490

COMMENTS: ____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.7 Hinge Assembly
This section contains the inspection requirements for non-destructive inspection of the hinge structure that
attaches the main cargo door to the main cargo door surround structure, and transfers load from the door to the
upper fuselage structure.
05-30-10
Feb. 11, 2015
7.7.1 Hinge Assembly Installation, HINGE-1
HI-1
TITLE: HINGE SEGMENTS - STATIONS [1] [2] [3] [4] [5] [6] [7]
370 TO 490 [8]

PEMCO”
NOTE: Production changes were incorporated as part of 007-00602, Revision F that specified an increased radius at the
“fingers” of the hinge. Aircraft delivered after December 31, 2005 incorporate these production changes and are subject
to a different inspection threshold than aircraft delivered prior to December 31, 2005 which do not incorporate these
production changes.
I. INSPECTION – HI-1
From the exterior of the aircraft, inspect the Hinge Assembly. This is a visual inspection of the PEMCO Hinge Assembly
from STA 370 to STA 490.
II. INSPECTION – HI-1-A, STEEL HINGE
From the exterior of the aircraft, inspect the Steel Hinge Assembly. This is an HFEC inspection of the PEMCO Steel Hinge
Assembly from STA 370 to STA 390 and STA470 to STA 490.
III. INSPECTION – HI-1-B, ALUMINUM HINGE
From the exterior of the aircraft, inspect the Aluminum Hinge Assembly. This is an HFEC inspection of the PEMCO
Aluminum Hinge Assembly from STA 390 to STA 470.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION HINGE-1
B737-200/300/400
DESCRIPTION: HINGE SEGMENTS STATIONS 370 - 490 OPERATOR: S/N:
POST MOD NiT Ni

STRUCTURE
JOB METHOD COUPON
FLIGHT
1
CYCLES
HINGE ASSY FS 370 TO 490 VISUAL 4000 4000
STEEL HINGES FS 370 – FS 390 HFEC 4000 4000

ALUMINUM HINGES FS 390 – FS
HFEC 20000 32000
470
COMMENTS: __(A) STEEL HINGE FS 370 – FS 390_____________________________________ __

___________ __(A) STEEL HINGE FS 470 – FS 490_______________________________________
_____________(B) ALUMINUM HINGE FS 390 – FS 470____________________________________
______________For aircraft modified prior to December 31, 2005_____________________________
1
ACCOMPLISHED BY: _____________________________________________________
INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
POST MOD NiT Ni

STRUCTURE
JOB METHOD COUPON
FLIGHT 1
CYCLES
HINGE ASSY FS 370 TO 490 VISUAL 4000 4000

ALUMINUM HINGES FS 390 – FS
HFEC 20000 32000
470
COMMENTS: __(A) STEEL HINGE FS 370 – FS 390_____________________________________ __

___________ __(A) STEEL HINGE FS 470 – FS 490_______________________________________
_____________(B) ALUMINUM HINGE FS 390 – FS 470____________________________________
______________For aircraft modified after December 31, 2005_____________________________
1
ACCOMPLISHED BY: _____________________________________________________
INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
05-30-10
Feb. 11, 2015
HINGE-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
RESULTS:
FS LOCATION
REPORT POSITIVE CRACK INDICATION AT FS LOCATION AS APPROPRIATE

COMMENTS: ____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.8 Frame Modification
This section contains the inspection requirements for non-destructive inspection of the frame structure that has
been modified to allow an eleven (11) pallet cargo configuration for 737-400 aircraft only.
Views of the pallet configurations for the 737-400 freighter aircraft are presented below. The eleven (11) pallet
cargo configuration that has the frame modification requiring specialized inspections is highlighted.
737-400 Eleven (11) Pallet Configuration Requiring

Specialized Inspection FRAME-1. This Inspection Applies
Only To 737-400 Aircraft With This Pallet Configuration.
05-30-10
EFFECTIVITY: 737-400 Page 133
Feb. 11, 2015
7.8.1 Frame Modification, FRAME-1
FRAME-1
TITLE: FUSELAGE FRAME FS1006 [1] [2] [3] [4] [5] [6] [7]

PEMCO”
NOTE: Production changes as part of an amendment to supplemental type certificate SA2968SO allowing an eleven (11)
pallet cargo configuration for 737-400 aircraft only, are addressed by this inspection requirement. Aircraft that are not
configured for the eleven (11) pallet cargo configuration shown in section 7.8 are not subject to this inspection
requirement.
I. INSPECTION – FRAME-1
From the interior of the aircraft, inspect the FS1006 frame modification. This is a visual inspection of the FS1006 frame
modification area from the forward and aft sides between stringer 15 and stringer 21, both left and right hand sides.
From the exterior of the aircraft, inspect the fuselage skin in the area of the FS1006 frame modification. This is a visual
inspection of the fuselage skin from FS1001 to FS1111 between stringer 15 and stringer 21, both left and right hand
sides.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION FRAME-1
B737-400
DESCRIPTION: FRAME FS1006 MODIFICATION OPERATOR: S/N:

Forward And Aft Sides of FS1006
Stringer 15 to Stringer 21

FS1001 to FS1111
Stringer 15 to Stringer 21
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
FUSELAGE SKIN VISUAL 4000 4000
FRAME AND FITTING VISUAL 8000 8000
COMMENTS: ______________________________________________________________________
Fuselage Skin – External, FS1001 to FS1111, Between Stringers 15 and 21 (Left and Right)________
Frame and Fitting – Internal, FS1006, Between Stringers 15 and 21 (Left and Right)_______________
______________ ___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
FRAME-1
JOB CARD B737-400
SHEET __1__ OF __1__
DESCRIPTION: FRAME FS1006 MODIFICATION OPERATOR: S/N:
RESULTS:
FS STR LOCATION
REPORT POSITIVE CRACK INDICATION AT FS AND STRINGER LOCATION AS APPROPRIATE

COMMENTS: ____________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.9 14 CFR 26.47
This section contains the inspection requirements for non-destructive inspection of the structure for compliance
with 14 CFR 26.47 requirements.
There is a non-destructive inspection of the hydraulic penetration in the aft wheel well bulkhead (HY-1). There is
a non-destructive inspection of the hydraulic penetration in the aft pressure bulkhead (HY-2). Aircraft that are
subject to HY-2, will also be subject to the inspections specified in HY-3 and HY-4.
Due to production variations, the doubler associated with HY-1 may be installed on either the forward or aft side
of the aft wheel well bulkhead. The inspection requirements of HY-1 are not impacted by the location of the
doubler installation.
Service Bulletin 737-29-0011 removes the hydraulic pump from the area aft of the aft pressure bulkhead and
moves it to the main landing gear bulkhead, where a penetration is made in the main landing aft wheel well
bulkhead. Service Bulletin 737-29-0011 caps the hydraulic lines at the aft pressure bulkhead and removes the
pump. Service Bulletin 737-29-0011 does not modify the structure that supported the hydraulic system aft of the
aft pressure bulkhead. Therefore, if Service Bulletin 737-29-0011 has been accomplished, aircraft are subject to
HY-1, HY-2, HY-3, and HY-4.
There is a non-destructive inspection of the smoke detection static ports (SP-1 and SP-2). A review of the type
design data showed that a configuration change for the SP-1 installation was incorporated for aircraft that have
been modified after March 11, 2001. The smoke detection static port (SP-1) is installed at the same location for
all modified aircraft. The different configurations have different inspection requirements. SP-1 and SP-2 only
apply to the 737-200 and 737-300 aircraft. The smoke penetration system installed for the 737-400 is governed
by the Goodrich Supplemental Type Certificate.
There are non-destructive inspections of the cargo compartment liner attachments to the fuselage frames (CC-1
through CC-6). CC-1 through CC-3 are only applicable to the full freighter versions of the 737-300. CC-4 applies
to the 737-400 Freighter, CC-5 applies to the 737-300, and CC-6 applies to the 737-400 Combination Freighter-
Passenger modification.
05-30-10
Feb. 11, 2015
7.9.1 Hydraulics Installation, HY-1

HY-1
TITLE: HYDRAULIC SYSTEM [1] [2] [3] [4] [5] [6] [7]
INSTALLATION, FS 727 WHEEL WELL FEED [8]
THROUGH DOUBLER
PEMCO”
[4] PEMCO Report 2966, Supplemental Corrosion Prevention Control Program, Boeing 737-300/400, Cargo
Door Installation”
I. INSPECTION – HY-1
As part of the Cargo Door Installation, a hydraulic tubes pass through is installed on the wheel well bulkhead at FS 727,
LBL 23.5.
The fasteners common to the wheel well bulkhead web and reinforcing doubler at FS 727 and LBL 23.5 are to be
inspected from forward and aft side of the FS 727 bulkhead using a detailed visual inspection.
The exposed wheel well bulkhead web at LBL 20 to LBL 27 is to be inspected between WL 170 and WL 185 from forward
and aft sides of the STA 727 bulkhead using a detailed visual inspection.
Due to production variations, the doubler may be installed on the forward or aft side of the aft wheel well bulkhead. The
doubler is to be inspected as installed on the STA 727 bulkhead between WL 170 and WL 185, and LBL 20 to LBL 27
using a detailed visual inspection.
Exterior access is from the MLG wheel well. The internal inspection requires removal of insulating blankets and floor
panels.
For aircraft modified prior to March 31, 2001, Service Bulletin 737-29-0011 removes the hydraulic pump from the area aft
of the aft pressure bulkhead and moves it to the main landing gear bulkhead, where a penetration is made in the main
landing aft wheel well bulkhead. Service Bulletin 737-29-0011 caps the hydraulic lines at the aft pressure bulkhead and
removes the pump. Service Bulletin 737-29-0011 does not modify the structure that supported the hydraulic system aft of
the aft pressure bulkhead.
Therefore, for aircraft modified prior to March 11, 2001, if Service Bulletin 737-29-0011 has not been accomplished,
aircraft are not subject to HY-1. Aircraft are still subject to HY-2, HY-3, and HY-4.
For aircraft modified prior to March 11, 2001, if Service Bulletin 737-29-0011 has been accomplished, aircraft are subject
For aircraft modified after March 11, 2001, the hydraulic pump was installed in the wheel well, and there was no relocation
of the hydraulic pump. Therefore, these aircraft are only subject to HY-1.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION HY-1
B737-200/300/400
DESCRIPTION: HYDRAULIC SYSTEM INSTALLATION, FS OPERATOR: S/N:
727 WHEEL WELL FEED THROUGH DOUBLER
Hydraulic Lines Wheel Well Bulkhead Pass-

Thru (FS 727, LBL 20-27, WL 176 - 182)
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
BULKHEAD WEB, DOUBLER, AND
VISUAL 8000 4000
STIFFENERS
COMMENTS: DETAILED INSPECTION FOR VISIBLE CRACKS IN BULKHEAD WEB AT THE _

FASTENERS COMMON TO THE WEB AND INSTALLED DOUBLER FROM FORWARD AND AFT _
SIDES OF THE BULKHEAD (FS 727) _
_
__________________________________________________________________________________
__________________________________________________________________________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: HYDRAULIC SYSTEM INSTALLATION, OPERATOR: S/N:
FS 727 WHEEL WELL FEED THROUGH DOUBLER
LBL 20 LBL 27
WL 185
WL 170
DOUBLER MAY BE INSTALLED

ON FORWARD OR AFT SIDE OF
THE BULKHEAD. INSPECTION
REQUIREMENTS ARE THE SAME
WL 185 FOR EITHER INSTALLATION.
UP
FWD DETAILED DETAILED

VISUAL VISUAL
WL 170
FS 727
05-30-10
Feb. 11, 2015
HY-1
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
FS 727 WHEEL WELL FEED THROUGH DOUBLER
LBL 20 LBL 27
WL 185
WL 170
RESULTS:
WL BL WL BL
REPORT POSITIVE CRACK INDICATION AT WL # AND BL # AS APPROPRIATE
COMMENTS: _____________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

HY-2
TITLE: HYDRAULIC SYSTEM [1] [2] [3] [4] [5] [6] [7]
INSTALLATION, FS1016 AFT PRESSURE [8]
BULKHEAD
PEMCO”
As part of the Cargo Door Installation, hydraulic tubes pass through the aft pressure bulkhead at FS1016, LBL 15, WL
200. There are two (2) different installations. One installation has four (4) connector penetrations, the other installation
has two (2) connector penetrations. Both installations are at the same location.
The exposed aft pressure bulkhead at LBL 10 to LBL 20 is to be inspected between WL 195 and WL 205 from forward
and aft sides of the FS 1016 bulkhead.
Access for this inspection is internal. The internal inspection from the forward side of the aft pressure bulkhead at FS1016
bulkhead requires removal of insulating blankets and floor panels. Internal inspection from the aftward side of the aft
pressure bulkhead at FS1016 requires access through the fuselage access panel in the lower skin between FS1040 and
FS1060.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
FS1016 AFT PRESSURE BULKHEAD
Hydraulic Lines Aft Pressure Bulkhead Pass-Thru

(FS 1016, LBL 10-20, WL 195-205)
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
BULKHEAD WEB, DOUBLER, AND
VISUAL 8000 4000
STIFFENERS
COMMENTS: DETAILED INSPECTION FOR VISIBLE CRACKS IN BULKHEAD WEB AND DOUBLER
FROM_FORWARD AND AFT SIDES OF THE BULKHEAD (FS 1016) ____
__________________________________________________________________ _
_ _
____________________________________________________________________________________
____________________________________________________________________________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION HYDRAULIC SYSTEM INSTALLATION, OPERATOR: S/N:
WL 205
WL 195
LBL 20 LBL 10
WL 205
WL 195
LBL 20
LBL 10
WL 205
UP
FWD DETAILED DETAILED

VISUAL VISUAL
WL 195
FS 1016
05-30-10
Feb. 11, 2015
HY-2
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
Both inspections are between

waterlines 195 and 205, and
between LBL 10 and 20.
RESULTS:
WL BL WL BL
REPORT POSITIVE CRACK INDICATION AT WL # AND BL # AS APPROPRIATE
COMMENTS: _____________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

HY-3
TITLE: HYDRAULIC SYSTEM PUMP [1] [2] [3] [4] [5] [6] [7]
INSTALLATION, FS 1040 THROUGH FS [8]
1088, STRINGER 17L THROUGH 23L
PEMCO”
As part of the Cargo Door Installation, a hydraulic pump installation is installed aft of the aft pressure bulkhead. Support
structure was installed to support the pump installation between FS 1040 and FS 1088, and between stringers S-17L and
S-23L.
The fuselage skin between FS 1040 and FS 1088, and between stringers S-17L and S-23L is to be inspected.
Access for this inspection is external.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: HYDRAULIC SYSTEM PUMP OPERATOR: S/N:
INSTALLATION, FS 1040 THROUGH FS 1088,
STRINGER 17L THROUGH 23L
UP
OUTBD
S-17L
DETAILED
VISUAL
S-23L
FUSELAGE
Hydraulic Pump Installation SKIN
(FS 1040 Through FS1088, Stringer 17L Through Stringer 23L)
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
FUSELAGE SKIN VISUAL 8000 4000
COMMENTS: DETAILED INSPECTION FOR VISIBLE CRACKS IN FUSELAGE SKIN FROM________

AIRCRAFT EXTERIOR BETWEEN FS 1040 AND FS 1088 AND BETWEEN STRINGER 17L AND_____
STRINGER 23L_ __________________________________________________________________ _
_ _
____________________________________________________________________________________
__________________________________________________________________ _________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
HY-3
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
DESCRIPTION: HYDRAULIC SYSTEM PUMP OPERATOR: S/N:
INSTALLATION, FS 1040 THROUGH FS 1088,
STRINGER 17L THROUGH 23L
UP
OUTBD
S-17L
DETAILED
VISUAL
S-23L
Hydraulic Pump Installation

(FS 1040 Through FS1088, Stringer 17L Through Stringer 23L) FUSELAGE
SKIN
RESULTS:
STR FS STR FS
REPORT POSITIVE CRACK INDICATION AT STR # AND FS # AS APPROPRIATE
COMMENTS: _____________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

HY-4
TITLE: HYDRAULIC LINE INSTALLATION, [1] [2] [3] [4] [5] [6] [7]
FS 947.5 THROUGH FS 1016, STRINGER [8]
22L THROUGH 23L
PEMCO”
As part of the Cargo Door Installation, a hydraulic pump installation is installed aft of the aft pressure bulkhead. In order
to support the hydraulic lines from the cargo door modification to the pump installation aft of the aft pressure bulkhead,
supports were added to the floor beams and the frames. The modified frames are to be inspected at the attachment of
the hydraulic line supports.
Support structure was installed to support the hydraulic line installation on the frames for the frames between FS 947.5
and FS 1016, and between stringers S-22L and S-23L. The frames are to be inspected from the aircraft interior.
Access for this inspection is internal. The internal inspection from the aircraft interior requires removal of insulating
blankets and floor panels
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300/400
DESCRIPTION: HYDRAULIC LINE INSTALLATION, FS OPERATOR: S/N:
947.5 THROUGH FS 1016, STRINGER 22L THROUGH
23L
UP
FWD
S-22L
DETAILED
VISUAL
(FWD & AFT)
S-23L
FRAME
WEB
Hydraulic Line Installation
(Fuselage Frames FS 947.5 Through FS 1016, Stringer 22L Through Stringer 23L)
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
FRAME WEB VISUAL 8000 4000
COMMENTS: DETAILED INSPECTION FOR VISIBLE CRACKS IN FUSELAGE FRAME WEB FROM
AIRCRAFT INTERIOR OF FRAMES BETWEEN FS 947.5 AND FS 1016 AND BETWEEN STRINGER_
22L AND STRINGER 23L. FRAMES TO BE INSPECTED FROM FORWARD AND AFT SIDES _
__________________________________________________________________ _ _ _
____________________________________________________________________________________
__________________________________________________________________ _________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
HY-4
JOB CARD B737-200/300/400
SHEET __1__ OF __1__
DESCRIPTION: : HYDRAULIC LINE INSTALLATION, OPERATOR: S/N:
FS 947.5 THROUGH FS 1016, STRINGER 22L
THROUGH 23L
UP
FWD
S-22L
DETAILED
VISUAL
(FWD & AFT)
S-23L
Hydraulic Line Installation
(Fuselage Frames FS 947.5
Through FS 1016, Stringer FRAME
22L Through Stringer 23L) WEB
RESULTS:
STR FS STR FS
REPORT POSITIVE CRACK INDICATION AT STR # AND FS # AS APPROPRIATE
COMMENTS: _____________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.9.5 Smoke Detector Static Port, SP-1

SP-1
TITLE: SMOKE DETECTOR SYSTEM [1] [2] [3] [4] [5] [6] [7]
STATIC PORT INSTALLATION – FORWARD -
FS 375
PEMCO”
I. INSPECTION – SP-1
SP-1 and SP-2 only apply to the 737-200 and 737-300 aircraft. The smoke penetration system installed for the 737-400 is
governed by the Goodrich Supplemental Type Certificate.
The forward static port doubler is installed on the fuselage skin at FS 375, LBL 31.86 and WL 161.48. A review of the
type design data showed that a configuration change for the SP-1 installation was incorporated for aircraft that have been
modified after March 11, 2001. The smoke detection static port (SP-1) is installed at the same location for all modified
aircraft. The different configurations have different inspection requirements.
The 0.063” thick 2024-T3 clad aluminum doubler is installed to reinforce the structure where the static ports pass through
the fuselage skin. The doubler is installed with NAS1097AD5 rivets.
The exposed fuselage skin between FS 365 and FS 385, and between STR 23L and STR 24L is to be inspected using a
detailed visual inspection from both the interior and exterior of the aircraft.
The doubler is to be inspected from the interior of the aircraft between FS 365 and FS 385, and between STR 23L and
STR 24L using a detailed visual inspection.
For the SP-1 installations installed after March 11, 2001, the fuselage skin is to be inspected using a high frequency eddy
current inspection centered on the fasteners.
The internal inspection requires removal of insulating blankets and floor panels.
05-30-10
EFFECTIVITY: 737-200/300 Page 152
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION SP-1
B737-200/300
FORM SHEET __1__ OF __3_
DESCRIPTION: SMOKE DETECTOR SYSTEM STATIC OPERATOR: S/N:
PORT INSTALLATION – FORWARD - FS 375
SP-1
After March 2001

Prior To March 2001
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
INTERNAL AND EXTERNAL FUSELAGE SKIN DETAILED
8000 4000
AND DOUBLER – PRIOR TO MARCH 2001 VISUAL

8000 8000
AND DOUBLER – AFTER MARCH 2001 VISUAL
INTERNAL FUSELAGE SKIN – AFTER MARCH HFEC @
16000 16000
2001 Fastener
COMMENTS: DETAILED INSPECTION FOR VISIBLE CRACKS IN FUSELAGE SKIN AT THE ___
FASTENERS COMMON TO THE SKIN AND INSTALLED DOUBLER FROM EXTERIOR AND_______
INTERIOR OF THE FUSELAGE ___
___
__________________________________________________________________________________
__________________________________________________________________ _______________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300
SP-1 Detailed Visual Inspection Area
FS 385
UP
FS 365
D
ILE
TA AL
DE ISU
V
D
A ILE L
T A
DE ISU
V
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300
S23L
Detailed Visual
HFEC
Detailed Visual
HFEC
S24L
HFEC Of Fuselage Skin At Fasteners

Inspection Area
FS365 FS385
Detailed Visual
Inspection Area
05-30-10
Feb. 11, 2015
SP-1
JOB CARD B737-200/300
SHEET __1__ OF __1__
FS 385
FS 365
RESULTS:
COMMENTS: _______________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
SP-1
JOB CARD B737-200/300
SHEET __1__ OF __1__
Detailed Visual
Inspection Area
FS365 FS385
S23L
Detailed Visual
HFEC
Detailed Visual
HFEC
S24L
HFEC Of Fuselage Skin At Fasteners

Inspection Area
RESULTS:
COMMENTS: _______________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.9.6 Smoke Detector Static Port, SP-2

SP-2
TITLE: SMOKE DETECTOR SYSTEM [1] [2] [3] [4] [5] [6] [7]
STATIC PORT INSTALLATION – AFT
FS 727E+5.0
PEMCO”
I. INSPECTION – SP-2
SP-1 and SP-2 only apply to the 737-200 and 737-300 aircraft. The smoke penetration system installed for the 737-400 is
governed by the Goodrich Supplemental Type Certificate.
The aft static port doubler is installed on the fuselage skin at FS 727E + 5.0, LBL 48.4 and WL 166.8.
The 0.063” thick 2024-T3 clad aluminum doubler is installed to reinforce the structure where the static ports pass through
the fuselage skin. The doubler is installed with NAS1097AD5 rivets.
The fasteners common to the fuselage skin and the static port doubler installation between FS 727E and FS 747, and
between STR 22L and STR 23L are to be inspected using a detailed visual inspection from the exterior and interior of the
aircraft.
The exposed fuselage skin between FS 727E and FS 747, and between STR 22L and STR 23L is to be inspected using a
detailed visual inspection from both the interior and exterior of the aircraft.
The doubler is to be inspected from the interior of the aircraft between FS 727E and FS 747, and between STR 22L and
STR 24L using a detailed visual inspection.
The internal inspection requires removal of insulating blankets and floor panels.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300
PORT INSTALLATION – AFT FS 727E+5.0
SP-2
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
8000 4000
AND DOUBLER VISUAL
COMMENTS: DETAILED INSPECTION FOR VISIBLE CRACKS IN FUSELAGE_ SKIN AT THE _ ___
FASTENERS COMMON TO THE SKIN AND INSTALLED DOUBLER FROM EXTERIOR AND_______
INTERIOR OF THE FUSELAGE _ ___
_________________
__________________________________________________________________________________
________________________________________________________________ _________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-200/300
SP-2 Detailed Visual Inspection Area
FS 747
FS 727E UP
D
ILE
TA AL
DE ISU
V
D
A ILE L
T A
DE ISU
V
05-30-10
Feb. 11, 2015
SP-2
JOB CARD B737-200/300
SHEET __1__ OF __1__
FS 747
FS 727E
RESULTS:
COMMENTS: _
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
7.9.7 Cargo Compartment Liner, CC-1

CC-1
TITLE: CARGO COMPARTMENT LINER [1] [2] [3] [4] [5] [6] [7]
INSTALLATION, LEFT AND RIGHT
EMERGENCY EXIT
PEMCO”
NOTE: Inspect inner and outer surface of frame inner chord.
NOTE: Fastener removal is not required.
NOTE: Applicable to 737-300 Full Freighter Only
I. INSPECTION – CC-1
The emergency exit door liner surround installation between STA 614 and STA 641 (left and right side) consists of 0.040”
thick by 2.0” wide strips and the strips are attached to the 007-04402-1 channel. The channel is attached to machined
frame at stations FS 616 and FS 639 via a 007-04402-51 zee.
From the interior of the aircraft between FS 610 and FS 620 (forward portion of the exit opening), between FS 635 and FS
645 (aft portion of the exit), and between WL 213 and WL 273, perform a detailed visual inspection, left and right side of
aircraft, of the fasteners, zees, frame, stringers, and channels associated with the installation prior to HFEC inspection.
Removal of the liner is required.
From the exterior of the aircraft between FS 610 and FS 645, and between WL 213 and WL 273 perform a visual
inspection, left and right side of aircraft, of the fuselage skin around the emergency door fuselage opening.
The inner and outer surfaces of the frame inner chord, at the fasteners, are to be inspected using a High Frequency Eddy
Current inspection at the following locations:
between FS 613 and FS 616, at WL 218 to WL 222, at WL 232 to WL 236, at WL 254 to WL 258, at WL 262 to WL 266
between FS 639 and FS 642, at WL 218 to WL 222, at WL 232 to WL 236, at WL 254 to WL 258, at WL 262 to WL 266
05-30-10
EFFECTIVITY: 737-300 Freighter Page 162
Feb. 11, 2015
ITEM: MODEL-SERIES:
DETAIL INSPECTION CC-1
B737-300 Freighter
DESCRIPTION: CARGO COMPARTMENT LINER OPERATOR: S/N:
INSTALLATION, LEFT AND RIGHT EMERGENCY EXIT
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
LH & RH SIDES INTERNAL – FS 610 TO FS 620 & DETAIL
8000 4000
FS 635 TO FS 645, BETWEEN WL 213 & WL 273 VISUAL
INNER SURFACES - FRAME INNER CHORD FS
HFEC 8000 4000
613 & FS 616 AND BETWEEN FS 639 & FS 642
LH & RH SIDES EXTERNAL – FUSELAGE SKIN, DETAIL

8000 4000
FS 610 TO FS 645, AND WL 213 TO WL 273 VISUAL
COMMENTS: DETAILED VISUAL INSPECTION OF INSTALLATION PRIOR TO HFEC INSPECTIONS

HFEC INSPECTION OF FRAME AT FASTENERS COMMON TO LINER ATTACHMENT AND FRAME__
CHORD INNER FLANGE AS INDICATED ON CC-1, SHEET 2 OF 2 __________________________
____________________________________________________________________________________
____________________________________________________________________________________
__________________________________________________________________ _________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-300 Freighter
HFEC Inspection Areas (Right & Left, Detail Shown Below)

Between FS 613 and FS 616, at WL 218-222, at WL 232-236, at WL 254-258, at WL 262-266, and
Between FS 639 and FS 642, at WL 218-222, at WL 232-236, at WL 254-258, at WL 262-266
FS 645 FS 635 FS 620 FS 610
WL 273 WL 273
WL 213 WL 213
Internal
Internal Visual and External Visual Visual
FS 644 FS 610
External Visual Removal Required
Exterior
HFEC
Interior exit opening

skin
05-30-10
Feb. 11, 2015
CC-1
JOB CARD B737-300 Freighter
SHEET __1__ OF __1__
FS 645 FS 635 FS 620 FS 610
WL 273 WL 273
WL 213 WL 213
RESULTS:
COMMENTS: _
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

CC-2
INSTALLATION -79, AFT PRESSURE
BULKHEAD
PEMCO”
Note: these inspection instructions (CC-2) pertain to the -79 liner installation only. The -59 closeout panels installation is
covered separately (CC-3). The installer is responsible for determining which inspection procedure applies.
The aft pressure bulkhead liner is attached to 0.063” thick 1.0” by 1.0” L-angles that span the width of the aft pressure
bulkhead. The angles are attached to the type design I-beams and lower structure using MS20426AD4 rivets.
From the interior of the aircraft, perform a detailed visual inspection the fasteners, angles, and I-beams associated with
the installation prior to HFEC inspection. The visual inspection includes an area 5.0 inch on either side of the I-Beams,
and extends the length of the I-Beams. Removal of the liner is necessary for access to the following inspection areas:
Left side: WL 222 to WL 293, and LBL 24 to LBL 34 (top), and LBL 42 to LBL 52 (bottom)
Right side: WL 222 to WL 295, and RBL 24 to RBL 34 (top), and RBL 42 to RBL 52 (bottom)
Report any abnormalities.
The inner surfaces of the aft pressure bulkhead I-Beam flanges attached to the angles to which the liner attaches are to
be inspected using a High Frequency Eddy Current inspection. The inspection areas are bounded as follows:
Left Side (FS1014 to FS 1017): Right Side (FS1014 to FS 1017):

WL 232 to WL 235, LBL 43 to LBL 45 WL 232 to WL 235, RBL 43 to RBL 45
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-300 Freighter
INSTALLATION -79, AFT PRESSURE BULKHEAD
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
DETAILED
INTERNAL - I-BEAMS 8000 8000
VISUAL
SURFACE OF THE AFT PRESSURE BULKHEAD
HFEC 8000 8000
I-BEAM FLANGES
COMMENTS: DETAILED VISUAL INSPECTION OF INSTALLATION PRIOR TO HFEC INSPECTIONS,

ZONES AS INDICATED ___________________
_____
HFEC INSPECTION OF INNER SURFACES OF THE AFT PRESSURE BULKHEAD I-BEAM FLANGES_
ATTACHED TO THE ANGLES AS INDICATED ON CC-2 SHEET 2 ____________
____________________________________________________________________________________
___________________________________________________________________ ________________
____________________________________________________________________________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-300 Freighter
HFEC Inspection Areas – Detail Shown Below
BL 34 BL 34
BL 24 BL 24
WL 293 WL 293
WL 290 WL 290
Typical section shown below
WL 225
WL 225
WL 222 WL 222
BL 52 BL 52
BL 42 BL 42
Internal Visual along and on either side of I-Beam
Aft HFEC of I-Beam at Fastener
Inboard
View Along I-Beam
Internal Visual
05-30-10
Feb. 11, 2015
CC-2
SHEET __1__ OF __1__
BL 34 BL 34
BL 24 BL 24
WL 293 WL 293
WL 290 WL 290
WL 225 WL 225
WL 222 WL 222
BL 52 BL 52
BL 42 BL 42
RESULTS:
WL LBL / RBL WL LBL / RBL
REPORT POSITIVE CRACK INDICATION AT WL # AND LBL/RBL # AS APPROPRIATE
COMMENTS: _
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

CC-3
INSTALLATION -59, AFT PRESSURE
BULKHEAD CLOSEOUTS
PEMCO”
Note: these inspection instructions (CC-3) pertain to the -59 closeout panels installation only. The -59 liner installation is
covered separately (CC-2). The installer is responsible for determining which inspection procedure applies.
The aft pressure bulkhead closeout consists of NB221-0155-375 honey comb panels attached to existing I-Beams using
brackets fastened with MS20470AD6 rivets.
From the interior of the aircraft, perform a detailed visual inspection the fasteners, angles, and I-beams associated with
the installation prior to HFEC inspection. The visual inspection includes an area 5.0 inch on either side of the I-Beams,
and extends the length of the I-Beams. Removal of the liner is necessary for access to the following inspection areas:
Left side: WL 222 to WL 293, and LBL 24 to LBL 34 (top), and LBL 42 to LBL 52 (bottom)
Right side: WL 222 to WL 295, and RBL 24 to RBL 34 (top), and RBL 42 to RBL 52 (bottom)
Report any abnormalities.
The inner surfaces of the aft pressure bulkhead I-Beam flanges attached to the brackets to which the panels attach are to
be inspected using a High Frequency Eddy Current inspection. The inspection areas are bounded as follows:
Left Side (FS1014 to FS 1017):

WL 237 to WL 245, LBL 43 to LBL 47 Right Side (FS1014 to FS 1017):
WL 273 to WL 281, LBL 30.5 to LBL 38.5 WL 255 to WL 263, RBL 37 to RBL 41
WL 273 to WL 281, RBL 30.5 to RBL 38.5
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-300 Freighter
CLOSEOUTS
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
DETAILED
INTERNAL - I-BEAMS 8000 8000
VISUAL
SURFACE OF THE AFT PRESSURE BULKHEAD
HFEC 8000 8000
I-BEAM FLANGES
COMMENTS: DETAILED VISUAL INSPECTION OF INSTALLATION PRIOR TO HFEC INSPECTIONS,

ZONES AS INDICATED ___________________
_____
HFEC INSPECTION OF INNER SURFACES OF THE AFT PRESSURE BULKHEAD I-BEAM FLANGES
ATTACHED TO THE ANGLES AS INDICATED ON CC-3 SHEET 2 ___________
___________________________________________________________________________________
___________________________________________________________________________________
_________________________________________________________________ _________________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-300 Freighter
CLOSEOUTS
HFEC Inspection Areas

Detail Below
BL 34
BL 34
BL 24
BL 24
WL 293
WL 293
WL 290
WL 290
WL 225 WL 225
WL 222 WL 222
BL 52 BL 52
BL 42 BL 42
Internal Visual along and on

either side of I-Beam
Typical section –
inspection area
HFEC of I-Beam at Fastener
Aft
Inboard
Internal Visual
Visual and HFEC inspections
requires removal of close-out panel View Along I-Beam
05-30-10
Feb. 11, 2015
CC-3
SHEET __1__ OF __1__
CLOSEOUTS
BL 34
BL 34
BL 24
BL 24
WL 293
WL 293
WL 290
WL 290
WL 225 WL 225
WL 222 WL 222
BL 52 BL 52
BL 42 BL 42
RESULTS:
WL LBL / RBL WL LBL / RBL
REPORT POSITIVE CRACK INDICATION AT WL # AND LBL / RBL # AS APPROPRIATE
COMMENTS: _______________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

CC-4
INSTALLATION, SIDEWALL
PEMCO”
reference Boeing 737 NDT Manual D6-37239.
NOTE: Permanent fastener removal is not required.
NOTE: Applicable to 737-400 Full Freighter only.
05-30-10
EFFECTIVITY: 737-400 Full Freighter Page 174
Feb. 11, 2015
Note: these inspection instructions, CC-4 (737-400 Full Freighter), differ from CC-5 (737-300 Full Freighter) instructions
with regard to frame callouts. The installer is responsible for determining which inspection procedure applies.
The typical liner sidewall isolators are installed on the inner chord of the frames (listed below) in nine (9) locations
between WL 213.15 and WL 293.08 (STR 5L/R to STR 17L/R). The J-23676-1 isolators are attached to frames using
MS20426AD4 rivets.
From the interior of the aircraft, prior to HFEC inspection, perform a detailed visual inspection the fasteners, isolators, and
inner and outer surfaces of the frame inner chord between STR 5 L/R and STR 17 L/R of frames associated with the
installation (listed below). Removal of the liner is required for the inspections. Report any abnormalities.
The surface of the frame inner chord between STR 5 L/R and STR 17 L/R, at the fasteners, is to be inspected using a
High Frequency Eddy Current inspection at the following locations:
STA 380 RH, STA 420 RH, STA 460 RH, STA 500 RH/LH, STA 500B RH/LH, STA 500D RH/LH, STA 500F RH/LH,
STA 520 RH/LH, STA 559 RH/LH, STA 601 RH/LH, STA 639 RH/LH, STA 685 RH/LH, STA 727 RH/LH,
STA 727B RH/LH, STA 727D RH/LH, STA 727F RH/LH, STA 747 RH/LH, STA 767 RH/LH, STA 787 RH/LH,
STA 827 RH/LH, STA 867 RH/LH, STA 907 RH/LH, STA 947.5 RH/LH
At each of the above frame stations inspect the isolator attachments at the inner chord of the frame at these locations:
WL 213.15, WL 223.5, WL 234.66, WL 237.45, WL 244.85, WL 256.87, WL 269.25, WL 284.0, and WL 293.08
Access to inspection areas in main cargo compartment.
- PRODUCTION VARIATION -
There is a production variation that allowed the installation of nut-plates and phenolic washers on the inner chord of the
left hand side of STA 500 between stringer 5L and 17L. At these locations, in lieu of the surface HFEC inspection at the
isolator attachments, perform a rotary hole HFEC of the open hole.
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-400 Full
FORM SHEET __1__ OF __2__ Freighter
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
INTERNAL - FRAME INNER & OUTER SURFACE DETAILED
8000 8000
AT FRAME INNER CHORD VISUAL
SURFACE OF THE FRAME INNER CHORD
HFEC 8000 8000
BETWEEN STR 5 L/R AND STR 17 L/R,
NUT – PLATE HOLES, FRAME INNER CHORD PRODUCTION

HFEC [1] 8000 8000
BETWEEN STR 5 L AND STR 17 L, FS500 [2] VARIATION
COMMENTS: DETAILED VISUAL INSPECTION OF FRAMES PRIOR TO HFEC __

INSPECTIONS BETWEEN STRG 5 AND STRG 17 __
__
HFEC INSPECTION OF FRAME INNER CHORD SURFACE AT ISOLATOR ATTACHMENTS AS __
INDICATED ON CC-4, SHEET 2 ______________________________________
__________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_
[1] REMOVE FASTENERS AND INSPECT HOLES WITH HFEC PROBE _________
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-400 Full
HFEC INSPECTION AREAS

(TYPICAL AT EACH FRAME)
(NOTE: APPLIES L&R SIDES)
VISUAL INSPECTION BETWEEN STR 5

AND STR 17 ON LEFT AND RIGHT SIDE
AT LOCATIONS SPECIFIED ABOVE
Typical section –
inspection area HFEC of Frame at Fastener
Internal Visual (liner removed)
Typical Frame
05-30-10
Feb. 11, 2015
CC-4
JOB CARD B737-400 Full
SHEET __1__ OF __1__ Freighter
RESULTS:
REPORT POSITIVE CRACK INDICATION AT STR # AND FRAME # AS APPROPRIATE
COMMENTS: _
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

CC-5
PEMCO”
NOTE: Applicable to 737-300 Full Freighter only.
05-30-10
Feb. 11, 2015
Note: these inspection instructions, CC-5 (737-300 Full Freighter), differ from CC-4 (737-400 Full Freighter) instructions
with regard to frame callouts. The installer is responsible for determining which inspection procedure applies.
The typical liner sidewall isolators are installed on the inner chord of the frames (listed below) in nine locations between
WL 213.15 and WL 285 (STR 5L/R to STR 17L/R). The J-23676-1 isolators are attached to frames using MS20426AD4
rivets.
-19 Installation - LEFT SIDE:

STA 360, STA 500, STA 500D, STA 580, STA 663, STA 727A, STA 727E, STA 807, STA 887, and STA 927
-19 Installation - RIGHT SIDE:

STA 360, STA 420, STA 500, STA 500D, STA 580, STA 663, STA 727A, STA 727E, STA 807, STA 887, and STA 927
-109 Installation - LEFT SIDE:

STA 360, STA 500, STA 540, STA 597, STA 685, STA 727B, STA 807, STA 887, STA 927
-109 Installation - RIGHT SIDE:

STA 360, STA 420, STA 500, STA 540, STA 597, STA 685, STA 727B, STA 807, STA 887, STA 927
WL 213.15, WL 219.92, WL 225.60, WL 234.68, WL 242.21, WL 256.87, WL 263.82, WL 273.10, and WL 285.0
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-300 Full
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
INTERNAL VISUAL INSPECTION – FRAMES VISUAL 8000 8000
FRAMES AT FASTENER LCCATIONS HFEC 8000 8000

HFEC [1] 8000 8000
COMMENTS: DETAILED VISUAL INSPECTION OF FRAMES PRIOR TO HFEC ___

INSPECTIONS BETWEEN STRG 5 AND STRG 17 ___
___
HFEC INSPECTION OF FASTENERS COMMON TO LINER ATTACHMENT ISOLATORS AND ___
FRAMES INNER CHORD AS INDICATED ON CC-5 SHEET 2 __________
___________________________________________________________________________
__________________________________________________________________________________
_________________________________________________________________ ________________
_
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-300 Full
HFEC Inspection Areas (typical at each frame)

(Note: applies to both left and right side)

Typical section –
HFEC of Frame inspection area
at Fastener
Typical Frame
05-30-10
Feb. 11, 2015
CC-5
JOB CARD B737-300 Full
SHEET __1__ OF __1__ Freighter
RESULTS:
COMMENTS: _
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015

CC-6
PEMCO”
NOTE: Applicable to 737-400 Combi only.
05-30-10
Feb. 11, 2015
Note: these inspection instructions, CC-6 (737-400 Combi), differ from CC-4 (737-400 Freighter) and CC-5 (737-300),
instruction with regard to frame callouts. The installer is responsible for determining which inspection procedure applies.
The typical liner sidewall isolators are installed on the inner chord of the frames (listed below) in nine locations between
WL 213.15 and WL 293.08 (STR 5L/R to STR 17L/R). The J-23676-1 isolators are attached to frames using
MS20426AD4 rivets.
LEFT SIDE:
STA 500, STA 500B, STA 500D, STA 500F, STA 520, STA 559, STA 578, and STA 601
RIGHT SIDE:
STA 380, STA 420, STA 500, STA 500B, STA 500D, STA 500F, STA 520, STA 559, STA 578, and STA 601
WL 213.15, WL 223.5, WL 234.66, WL 237.45, WL 244.85, WL 256.87, WL 269.25, WL 284.00, and WL 293.08.0
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-400 Combi
POST MOD NiT Ni

JOB METHOD COUPON
STRUCTURE FLIGHT
CYCLES
INTERNAL VISUAL INSPECTION – FRAMES VISUAL 8000 8000
FRAMES AT FASTENER LCCATIONS HFEC 8000 8000

HFEC [1] 8000 8000
COMMENTS: DETAILED VISUAL INSPECTION OF FRAMES PRIOR TO HFEC ___

INSPECTIONS BETWEEN STRG 5 AND STRG 17 ___
___
HFEC INSPECTION OF FASTENERS COMMON TO LINER ATTACHMENT ISOLATORS AND ___
FRAMES INNER CHORD AS INDICATED ON CC-6 SHEET 2 __________
___________________________________________________________________________
__________________________________________________________________________________
_________________________________________________________________ ________________
_
ACCOMPLISHED BY: ______________________________________________________________

INSPECTOR: ______________________________________________________________
05-30-10
Feb. 11, 2015
ITEM: MODEL-SERIES:
B737-400 Combi
HFEC Inspection Areas (typical at each frame)

(Note: applies to both left and right side)

Typical section –
HFEC of Frame inspection area
at Fastener
Typical Frame
05-30-10
Feb. 11, 2015
CC-6
SHEET __1__ OF __1__
RESULTS:
COMMENTS: _
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
ACCOMPLISHED BY: _____________________________________________________

INSPECTOR: _____________________________________________________
05-30-10
Feb. 11, 2015
8. INSPECTION COUPONS
This section contains the details required for manufacturing of the low frequency eddy current calibration coupons. It is
noted that with Revision 5 (dated April 29, 2003) of this manual, coupons were deleted that are no longer required.
Because the coupons specified by earlier revisions of this document have already been constructed, the coupon
numbering system was not changed. Qualified procedures and reference standards are given in Appendices A and B.
The inspections given in Appendices A and B are Low Frequency Eddy Current inspections from the exterior of the
aircraft for ED-1, ED-2, ED-6, and ED-7. Based on input of operators, a number of false positives may be reported for
these inspections. Per operator request, inspections at the first fastener row may be performed from the interior of the
aircraft (LFEC probe is on the 0.028” thick stringer and not on the 0.090” doubler), provided the reference standard given
in Appendix A or B is used. Per operator request, where accessible, the second fastener row may be inspected using a
HFEC current probe at the fastener head (reference Boeing 737 NDT Manual D6-37239) from the interior of the aircraft.
The validation of the process and procedures used for the inspection coupons contained in this section is left to the
operator. It is permissible to use the processes and procedures given in the Boeing 737 NDT Manual D6-37239, or
Appendix A and B contained in this manual (P03-007MM), to develop valid inspection processes and procedures for the
coupons contained in this section.
05-30-10
Feb. 11, 2015
8.1 Coupon Number 2
This coupon is for use with inspection ED-4.
LOW FREQUENCY EDDY CURRENT STANDARD
1.0 IN 0.240 IN
0.100 IN
A A
5.0 IN 1.0 IN
1
1.0 IN
1.0 IN
3.0 IN
LFEC
AL 2024-T3 MS20426DD6 0.090 IN

0.240 IN
0.100 IN 0.036 IN
AL 2024-T3
0.240 IN 0.036 IN
AL 2024-T3 1
2
SECTION A-A
NOTES
○ ALL DIMENSIONS ARE IN INCHES
○ TOLERANCE: X.X + 0.05 INCHES
X.XXX + 0.005 INCHES
○ MATERIAL: AS DESIGNATED ABOVE
JEWLER’S SAWCUT 0.030 INCH MAX WIDTH

1 LENGTH OF 0.240 INCHES
2 SEAL PER MIL-S-81733 TYPE IV-48 BETWEEN

BOEING AIRCRAFT SKIN AND DOUBLER
COUPON No. 2 – LOW FREQUENCY EDDY CURRENT STANDARD
05-30-10
Feb. 11, 2015
8.2 Coupon Number 3
1.0 IN 0.240 IN
0.100 IN
A A
5.0 IN 1.0 IN
1
1.0 IN
1.0 IN
3.0 IN
LFEC
AL 2024-T4 MS20426DD6 0.090 IN

0.240 IN
0.100 IN
AL 2024-T3
0.240 IN
0.036 IN
1
SECTION A-A
NOTES

05-30-10
Feb. 11, 2015
8.3 Coupon Number 6
1.0 IN 0.240 IN
0.100 IN
A A
5.0 IN 1.0 IN
1
1.0 IN
1.0 IN
3.0 IN
LFEC
PEMCO
DOUBLER
AL 2024-T4 MS20426DD6
0.240 IN 0.090 IN
BOEING 0.100 IN
BEARSTRAP 0.100 IN
AL 2024-T3 0.036 IN
BOEING
A/C SKIN
AL 2024-T3
BOEING 0.240 IN 0.036 IN
A/C DOUBLER 1
AL 2024-T3 2
SECTION A-A
NOTES

2 SEAL PER MIL-S-81733 TYPE IV-48
05-30-10
Feb. 11, 2015
8.4 Coupon Number 12
1.0 IN 0.240 IN
0.100 IN
A A
5.0 IN 1.0 IN
1
1.0 IN
1.0 IN
3.0 IN
LFEC
PEMCO
SPLICE
AL 2024-T3 MS20426DD6
0.240 IN 0.090 IN
PEMCO 0.090 IN
DOUBLER 0.100 IN
AL 2024-T3 0.036 IN
BOEING
A/C SKIN
AL 2024-T3
A/C DOUBLER 1
AL 2024-T3 2
SECTION A-A
NOTES

05-30-10
Feb. 11, 2015
This coupon is for use with inspection UJ-1.
1.0 IN 0.240 IN
0.100 IN
A A
5.0 IN 1.0 IN
1
1.0 IN
1.0 IN
3.0 IN
LFEC
AL 7075-T6 NA623-3
0.240 IN 0.125 IN
0.100 IN
AL 7075-T73
0.240 IN 0.125 IN
1
SECTION A-A
NOTES

05-30-10
Feb. 11, 2015
This coupon is for use with inspection ED-3 and ED-4.
1.0 IN 0.240 IN
0.100 IN
A A
5.0 IN 1.0 IN
1
1.0 IN
1.0 IN
0.956 IN
3.0 IN
LFEC
AL 2024-T4 MS20426DD6 0.090 IN

0.240 IN
0.100 IN 0.036 IN
AL 2024-T3
0.036 IN
AL 2024-T3 1 0.028 IN
2 0.240 IN
AL 7075-T6
SECTION A-A
NOTES

2 SEAL PER MIL-S-81733 TYPE IV-48 BETWEEN

BOEING AIRCRAFT SKIN AND DOUBLER
05-30-10
Feb. 11, 2015
1.0 IN 0.240 IN
0.100 IN
A A
5.0 IN 1.0 IN
1
1.0 IN
1.0 IN
0.956 IN
3.0 IN
LFEC
PEMCO
DOUBLER MS20426DD6
AL 2024-T4 0.240 IN 0.090 IN
BEARSTRAP 0.036 IN
AL 2024-T3
BOEING
A/C SKIN
AL 2024-T3
BOEING
A/C DOUBLER 2 1 0.036 IN 0.028 IN
0.240 IN
AL 2024-T3
STRINGER
AL 7075-T6 SECTION A-A
NOTES

05-30-10
Feb. 11, 2015
APPENDIX A
05-30-10
EFFECTIVITY: ALL
Sept. 1, 2006
March 4, 2004
Eddy Current
Fuselage Skin Surrounding the Main Deck Cargo Door
1. Purpose
A. Use this low frequency eddy current inspection to find cracks in the skin beneath an
external doubler from STA 312 to STA 500B as follows: See Fig. 1.
(1) STR 3R fastener row and the fastener row below STR 3R.
(2) STR 23L fastener row and the fastener row above STR 23L.
B. This low frequency eddy current procedure uses an impedance plane display
instrument.
2. Equipment
A. General
(1) Use inspection equipment that can be calibrated on the reference standard as
specified in paragraph 4.
B. Instrument
(1) Use an impedance plane display instrument that operates at a frequency range of
500Hz to 950Hz.
(2) A Nortec 1000 eddy current instrument was used to help prepare this procedure.
C. Probe
(1) One probe is necessary to do this procedure
(a) A reflection type ring probe with an inner diameter of 0.45 inch (11.4mm)
and an outer diameter of 0.9 (22.8mm) that operates at 900 and 950Hz.
(2) The NDT Engineering probe followed by its part number was used to help
develop this procedure.
(a) Ring probe, RR017-1/TF.

NOTE: Make sure you tell the probe manufacturer the eddy current instrument you
will use with the probes. The above probe has a Trix Fisher connector. The
probe cable will have to be ordered separately.
3. Preparation for Inspection
A. Find the inspection areas. See Fig.1 and 5.
B. Get access to STR 3R and STR 23L from STA 312 to STA 500B
C. Remove dirt, grease and loose paint from the inspection areas that the probe will touch.
See Fig. 1 and 5.
4. Instrument Calibration
Two instrument calibrations are necessary, a calibration for fasteners in STR 3R and STR
23L and a calibration for fasteners in the row below STR 3R and above STR 23L.
A. Calibrate your equipment to examine the skin beneath the external doubler in STR 3R
and STR 23L as follows:
(1) Set the instrument frequency to 900 Hz.
(2) Connect the probe to the instrument.
(3) Put the ring probe at probe position 1. Center the probe above the fastener
head. See Fig. 3, flag note 1.
(4) Balance the instrument as specified by the manufacturer’s instructions.
(5) Move the probe above the fastener to get a minimum full screen height (FSH)
signal response.
(6) Set the balance point at approximately 20% of FSH and 60% full screen width
(FSW). See Fig. 4, Screen Display 1.
(7) Set the lift-off (phase) so that the signal moves horizontally from right to left
when the probe is lifted off the reference standard. See Fig. 4, Screen Display
1.
(8) Put the probe at probe position 2 as shown in Fig.3, flag note 2. Make sure the
fastener is in the center of the probe. Move the probe above the fastener to get a
minimum FSH signal response.
(9) Monitor the signal on the screen display from the notch at probe position 2. See
Fig.4, Screen Display 2.
2
(10) Adjust the instrument gain to get a notch signal that is approximately 40% of
FSH above the balance point. See Fig. 4 Screen Display 2
(11) Do par 4.A. (3), (4), (5), (8) and (9) again to make sure that there is 40%
separation between the un-notched and notched fastener holes. See Fig. 3, flag
notes 1 and 2 and Fig. 4.
(12) Do par 4A. (3) through (10) again if the notched signal is not at 40% FSH
above the balance point.
B. Calibrate your equipment to examine the skin beneath the external doubler in the
fastener row below STR3R and the fastener row above STR 23L as follows:
(3) Put the probe at probe position 3. Center the probe above the fastener head.
See Fig. 3, flag note 3.
(4) Do par 4.A. (3) through (7) again except at probe position 3. See Fig. 3 flag
note 3 and Fig. 4.
(5) Do par 4.A. (8) through (12) except at probe position 4. See Fig. 3, flag note 4
and Fig.4.
5. Inspection Procedure
A. Examine the fastener holes in the skin at STG 3R from STA 312 to STA 500B. Do not
examine fasteners holes in the external splice plate locations. See Fig 1 and Fig. 5, flag
note 1.
NOTE: The skin is covered by the external doubler.
(1) Get access to the top of the airplane and identify the inspection area at STR 3R.
See Fig. 1 and 5 Sheet 1.
(2) Calibrate the instrument per par 4.A. to examine fastener holes in STR 3R.
(3) Put the probe above an inspection fastener. Make sure the fastener is in the center
of the probe. See Fig. 5, flag note 3.
(4) Move the probe above the fastener as necessary to get a minimum FSH signal.
Monitor the instrument screen display while you move the probe to get the
airplane standard (baseline). See Fig. 5 Sheet 1, flag note 3.
3
(5) Balance the instrument to put the signal from the fastener hole at approximately
20% full screen height.
NOTE: Do not change the instrument sensitivity when you put the fastener
signal at 20% full screen height.
(6) Do par 5.A. (3) and (4) again a minimum of 3 times at different fastener hole
locations in STR 3R to get the standard (or baseline) signal for a satisfactory
fastener location (no crack in the skin).
NOTE: It is possible that a fastener hole you used to get the standard (baseline)
was cracked. If this occurred, all fastener holes that are not cracked
will have a screen signal below the balance point. Put the probe on a
different inspection fastener hole if you think you set-up on a cracked
fastener hole.
(7) Make a note of the fastener hole locations you used to get the airplane standard
(baseline) signal. Refer to these fastener holes to do a check of your calibration
during the inspection.
(8) Examine all of the fasteners that are identified in the fastener row STR 3R.
NOTE: Do not examine fasteners holes in the splice plate locations.
(9) Make a record of fastener hole locations that cause signals that are 30% FSH or
more above the balance point.
B. Examine the fastener holes in the skin at the fastener row below to STG 3R from STA
312 to STA 500B. The inspection fastener row is the first fastener row down from STR
3R. Do not examine fasteners holes in the external splice plate locations. See Fig 1
and Fig. 5, flag note 2.
(1) Get access to the top of the airplane and identify the inspection area. See Fig. 1
and Fig, 5.
(2) Calibrate the instrument per par 4. B. to examine the fastener row below STR 3R.
(3) Do par. 5.A. (3) through (9) except at the first fastener row below to STR 3R
fastener row. See Fig. 5, flag note 2.
C. Examine the fastener holes in the skin at STG 23L from STA 312 to STA 500B. Do
not examine fasteners holes in the external splice plate locations. See Fig 1 and Fig. 5,
flag note 1. This fastener row is adjacent to the external doubler lower edge.
4
(1) Get access to the bottom of the airplane and identify the inspection area at STR
23L.
(2) Calibrate the instrument per par 4.A. to examine fastener holes in STR 23L.
(3) Do par. 5.A. (2) through (9) except at the fastener holes in STR 23L from STA
312 to STA 500B. See Fig 1 and Fig. 5, flag note 1.
D. Examine the fastener holes in the skin at the fastener row above to STG 23L from STA
312 to STA 500B. The inspection fastener row is the first fastener row up from STR
23L in the external doubler. Do not examine fasteners holes in the external splice plate
locations. See Fig 1 and Fig. 5, flag note 2.
(1) Get access to the bottom of the airplane and identify the inspection area.
(2) Calibrate the instrument per par 4. B. to examine the fastener row above STR
23L.
(3) Do par. 5. A. (3) through (9) except at the fastener row above to STR 23L. See
Fig. 5. Sheet 2, flag note 2
6. Inspection Results
A. A signal that is 30% or more of FSH above the balance point can be an indication of a
possible crack.
(1) Compare the signal that occurs during the inspection to the signal you got from
the notch in the reference standard
B. It is possible that the first fastener hole you used to get the airplane standard baseline
was cracked. If this occurred all fastener holes that are not crack will have a screen
signal below the balance point. If you think you set-up on a cracked fastener hole, put
the probe on a different inspection fastener hole to get the airplane standard (baseline).
C. To make sure a fastener hole is cracked, remove the fastener and do a high frequency
eddy current open fastener hole inspection.
5
APPENDIX B
05-30-10
EFFECTIVITY: ALL
Sept. 1, 2006
March 16, 2004
Eddy Current
Fuselage Skin Surrounding the Main Deck Cargo Door
(External Splice Plate Areas)
1. Purpose
A. Use this low frequency eddy current inspection to find cracks in the fuselage skin. The
skin areas that are examine are below an external splice plate and an external doubler at
the Body Station (BS) 340, BS 386.5, BS 431.5, and BS 473.5. Examine the fastener
holes in the fuselage skin at the Stringer (STR) locations as follows (See Fig1):
(1) STR 3R fastener row and the fastener row below STR 3R.
(2) STR 23L fastener row and the fastener row above STR 23L.
B. This low frequency eddy current procedure uses an impedance plane display
instrument.
2. Equipment
A. General
(1) Use inspection equipment that can be calibrated on the reference standard as
specified in paragraph 4.
B. Instrument
(1) Use an impedance plane display instrument that operates at a frequency range of
500Hz to 950Hz.
(2) A Nortec 1000 eddy current instrument was used to help prepare this procedure.
C. Probe
(1) One probe is necessary to do this procedure
(a) A reflection type ring probe with an inner diameter of 0.45 inch (11.4mm)
and an outer diameter of 0.9 (22.8mm) that operates at 900 and 950Hz.
(2) The NDT Engineering probe followed by its part number was used to help
develop this procedure.
(a) Ring probe, RR017-1/TF.
NOTE: Make sure you tell the probe manufacturer the eddy current instrument you
will use with the probes. The above probe has a Trix Fisher connector. The
probe cable will have to be ordered separately.
3. Preparation for Inspection
A. Find the inspection areas. See Fig.1 and 5.
B. Get access to STR 3R and STR 23L from STA 312 to STA 500B
C. Remove dirt, grease and loose paint from the inspection areas that the probe will touch.
See Fig. 1 and 5.
4. Instrument Calibration
Two instrument calibrations are necessary, a calibration for fasteners in STR 3R and STR
23L and a calibration for fasteners in the row below STR 3R and above STR 23L.
A. Calibrate your equipment to examine the skin below the external splice plate and
external doubler in STR 3R and STR 23L as follows:
(3) Put the ring probe at probe position 1. Center the probe above the fastener
head. See Fig. 3, flag note 1.
(4) Balance the instrument as specified by the manufacturer’s instructions.
(5) Move the probe above the fastener to get a minimum full screen height (FSH)
signal response. Balance the instrument again.
(6) Set the balance point at approximately 20% of FSH and 60% full screen width
(FSW). See Fig. 4, Screen Display 1.
(7) Set the lift-off (phase) so that the signal moves horizontally from right to left
when the probe is lifted off the reference standard. See Fig. 4, Screen Display
1.
2
(8) Put the probe at probe position 2 as shown in Fig.3, flag note 2. Make sure the
fastener is in the center of the probe. Move the probe above the fastener to get a
minimum FSH signal response.
(9) Monitor the signal on the screen display from the notch at probe position 2. See
Fig.4, Screen Display 2.
(10) Adjust the instrument gain to get a notch signal that is approximately 40% of
FSH above the balance point. See Fig. 4 Screen Display 2
(11) Do par 4.A. (3), (4), (5), (8) and (9) again to make sure that there is 40%
separation between the un-notched and notched fastener holes. See Fig. 3, flag
notes 1 and 2 and Fig. 4.
(12) Do par 4A. (3) through (10) again if the notched signal is not at 40% FSH
above the balance point.
B. Calibrate your equipment to examine the skin below the external splice plate and
external doubler in the fastener row below STR3R and the fastener row above STR
23L as follows:
(3) Put the probe at probe position 3. Center the probe above the fastener head.
See Fig. 3, flag note 3.
(4) Do par 4.A. (3) through (7) again except at probe position 3. See Fig. 3 flag
note 3 and Fig. 4.
(5) Do par 4.A. (8) through (12) except at probe position 4. See Fig. 3, flag note 4
and Fig.4.
5. Inspection Procedure
A. Examine the fastener holes in the skin at STG 3R at BS 340, BS 386.5, BS 431.5, and
BS 473.5. The skin is covered by the external splice plate and external doubler. See
Fig 1 and Fig. 5 Sheet 1, flag note 1.
(1) Get access to the top of the airplane and identify the inspection area at STR 3R.
See Fig. 1 and 5 Sheet 1.
(2) Calibrate the instrument per par 4.A. to examine fastener holes in STR 3R.
(3) Put the probe above an inspection fastener. Make sure the fastener is in the center
of the probe. See Fig. 5, flag note 3.
3
(4) Move the probe above the fastener as necessary to get a minimum FSH signal.
Monitor the instrument screen display while you move the probe to get the
airplane standard (baseline) signal. See Fig. 5 Sheet 1, flag note 3.
(5) Balance the instrument to put the signal from the fastener hole at approximately
20% full screen height.
NOTE: Do not change the instrument sensitivity when you put the fastener
signal at 20% full screen height.
(6) Do par 5.A. (3) and (4) again a minimum of 3 times at different fastener hole
locations in STR 3R to get the standard (or baseline) signal for a satisfactory
fastener location (no crack in the skin).
NOTE: It is possible that a fastener hole you used to get the standard (baseline)
was cracked. If this occurred, all fastener holes that are not cracked
will have a screen signal below the balance point. Put the probe on a
different inspection fastener hole if you think you set-up on a cracked
fastener hole.
(7) Make a note of the fastener hole locations you used to get the airplane standard
(baseline) signal. Refer to these fastener holes to do a check of your calibration
during the inspection.
(8) Examine all of the fasteners that are identified in the fastener row STR 3R.
(9) Make a record of fastener hole locations that cause signals that are 30% FSH or
more above the balance point.
B. Examine the fastener holes in the skin at the fastener row below STG 3R at BS 340, BS
386.5, BS 431.5, and BS 473.5. The inspection fastener row is the first fastener row
down from STR 3R. See Fig 1 and Fig. 5 Sheet 1, flag note 2.
NOTE: The skin is covered by the external splice plate and external doubler.
(1) Get access to the top of the airplane and identify the inspection area. See Fig. 1
and Fig. 5, Sheet 1.
(2) Calibrate the instrument per par 4. B. to examine the fastener row below STR 3R.
(3) Do par. 5.A. (3) through (9) except at the first fastener row below to STR 3R
fastener row. See Fig. 5, flag note 2.
4
C. Examine the fastener holes in the skin at STG 23L at BS 340, BS 386.5, BS 431.5, and
BS 473.5. The skin is covered by the external splice plate and external doubler. See
Fig 1 and Fig. 5 Sheet 2, flag note 1.
(1) Get access to the bottom of the airplane and identify the inspection area at STR
23L.
(2) Calibrate the instrument per par 4.A. to examine fastener holes in STR 23L.
(3) Do par. 5.A. (2) through (9) except at the fastener holes in STR 23L external
splice plate locations. See Fig 1 and Fig. 5 Sheet 2 flag note 1.
D. Examine the fastener holes in the skin at the fastener row above STG 23L at BS 340,
BS 386.5, BS 431.5, and BS 473.5. The inspection fastener row is the first fastener row
up from STR 23L. See Fig 1 and Fig. 5 Sheet 2, flag note 2.
NOTE: The skin is covered by the external splice plate and external doubler.
(1) Get access to the bottom of the airplane and identify the inspection area.
(2) Calibrate the instrument per par 4. B. to examine the fastener row above STR
23L.
(3) Do par. 5. A. (3) through (9) except at the fastener row above to STR 23L. See
Fig. 5. Sheet 2, flag note 2
6. Inspection Results
A. A signal that is 30% or more of FSH above the balance point can be an indication of a
possible crack.
(1) Compare the signal that occurs during the inspection to the signal you got from
the notch in the reference standard
B. It is possible that the first fastener hole you used to get the airplane standard baseline
was cracked. If this occurred all fastener holes that are not crack will have a screen
signal below the balance point. If you think you set-up on a cracked fastener hole, put
the probe on a different inspection fastener hole to get the airplane standard (baseline).
C. To make sure a fastener hole is cracked, remove the fastener and do a high frequency
eddy current open fastener hole inspection.

p03-007mm Ssid Revision 17

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

p03-007mm Ssid Revision 17

Uploaded by

Copyright:

Available Formats

LOG OF REVISIONS

REVISION DATE PAGES DESCRIPTION OF REVISION APPROVAL

1 30-May-96 - Initial Release

Updated to Include Inspections and

Updated To Allow the use of Visual Aides,

Complete Revision and Re-Issue.

Inspection Intervals Changed to Reflect

REVISION DATE PAGES DESCRIPTION OF REVISION APPROVAL

Complete Revision and Reissue.

737-400 Inspection Program Added.

Complete Revision and Reissue.

737-400 Freighter-Passenger Combi

STC Numbers removed from Title Page

Complete Revision and Reissue.

737-400 Freighter-Passenger Combi

Minor Corrections Made Based On

Unreleased Revision That Addressed 14

Complete Revision and Re-Issue

Update Table 2Error! Reference source

REVISION DATE PAGES DESCRIPTION OF REVISION APPROVAL

Complete Revision and Re-Issue

Existing Table 2 Becomes Table 3.

Removed aircraft serial numbers 24277,

Removed aircraft serial number 23499,

REVISION DATE PAGES DESCRIPTION OF REVISION APPROVAL

Revised SP-1 to account for two

Revised SP-1 and SP-2 to show only for

Clarified EX-1, UJ-2, and HY-1 inspection

Revised inspection requirments of ED-9.

Clarified aircraft configuration for CC-4 and Hal Horsburgh

Clarified CD-1 through CD-4 configurations

Clarified Applicablity of FRAME-1

Changed contact information.

Removed serial number table for 11 pallet

REVISION DATE PAGES DESCRIPTION OF REVISION APPROVAL

Clarified Inpsection ED-9 as applying to all

Clarified Inspection Requirements Of CD-1

Clarified Longitudinal Floor Beam

Added Boeing D6-82669 Document

Specified GPS, TCAS, and ATC Antenna

Clarified Coupon Requirements.

Updated To Include Inspection Instructions

LOG OF REVISIONS .............................................................................................................................................................. 2

7.7 Hinge Assembly ................................................................................................................................................. 127

2.1 Operator’s Initial Report

Contact Pemco Product Support at:

2.2 PEMCO Follow Up Action

3.1 General Instructions

4.1 Visual Inspection

4.2 Fluorescent-Penetrant (F-P) Inspection

4.3 Eddy Current Inspection

2. Description: Gives a brief description of the area being inspected.

12. Method (NDT): Identifies the method of inspection to be used.

RIVETS, R1C1-R1Ci LFEC 8000 4000

Figure 1: Sample Detailed Inspection Form

FLIGHT CYCLES ITEM: MODEL-SERIES:

ROW COLUMN ROW COLUMN ROW COLUMN

REPORT POSITIVE CRACK INDICATION AT ROW # AND COLUMN # APPROPRIATE

COMMENTS: _____ USE S-3R LFEC PROCEDURE IN APPENDIX A ________________________

ACCOMPLISHED BY: _____________________________________________________

Figure 2: Sample Job Card

NOTE: See latest revision of listed document.

TABLE 1: Airworthiness Directives and Service Bulletins

6.1 Effective Aircraft

COMMENTS: _ USE S-3R LFEC PROCEDURE IN APPENDIX A ____________________

COMMENTS: _MCD IS INCLUDED IN THIS INSPECTION_ _____________________________

COMMENTS: ____[1] USE S-3R LFEC PROCEDURE IN APPENDIX A – EXTERIOR _

COMMENTS: [1] USE S-3R LFEC PROCEDURE IN APPENDIX A – EXTERIOR