Technical Training Manual Boeing 737-600/-700/-800/-900 from Bostonair Technical Training Limited

TABLE OF CONTENTS

1
Structures
- 5 -

General Structures

3.3.1
General.
. 30

Introduction to Structures

1.1
Introduction.

Basic Structural Description

1.1.1
Basic structural description
- 5 -

High Fatigue Design Life

1.1.2
High fatigue design life
- 7 -

Corrosion Prevention

1.1.3
Corrosion prevention
- 7 -

Definitions

1.1.4
Definitions
- 7 -

Composite Material

1.2
Composite material
10 -

Composite Material Introduction

1.2.1
Introduction
10 -

General Composite Material

1.2.2
General.
- 10 -

Fuselage

2
Fuselage
12 -

Fuselage Introduction

2.1
Introduction
12 -

General Fuselage

2.1.1
General
12 -

Nose Radome

2.2
Nose radome
15 -

Main Frame

2.3
Main frame
- 16 -

Airframe Drain Holes

2.4
Airframe Drain Holes.
- 26 -

General Drain Holes

2.4.1
General.
- 26 -

External Drains

2.4.2
External Drains.
26 -

Internal Drain Paths & Drain Holes

2.4.3
Internal Drain Paths & Drain Holes.
26 -

Nacelles and Pylons

3
Nacelles and pylons
28

General Nacelles and Pylons

3.1
General
28 -

Strut Structure

3.2
Strut Structure.
28 -

Nacelle Strut

3.3
Nacelle Strut
30 -

Auxiliary Structure

3.4
Auxiliary Structure.
32 -

General Auxiliary Structure

3.4.1
General.
- 32 -

Access Panels

3.4.2
Access Panels.
32 -

Fairings

3.4.3
Fairings.
- 32 -

Forward Fairing

3.4.4
Forward Fairing.
32 -

Engine Attach Fittings

3.5
Engine Attach Fittings.
34 -

General Engine Attach Fittings

3.5.1
General.
34 -

Stabilizer

4
Stabilizer
35 -

Horizontal Stabilizer

4.1
Horizontal Stabilizer.
35 -

General Horizontal Stabilizer

4.1.1
General.
35 -

Stabilizer Structure

4.1.2
Stabilizer Structure.
35 -

Elevator

4.2
Elevator.
37 -

General Elevator

4.2.1
General
37

Elevators

4.2.2
Elevators

Elevator Control Tabs

4.2.3
Elevator Control Tabs.
- 37 -

Vertical Stabilizer

4.3
Vertical Stabilizer
39

General Vertical Stabilizer

4.3.1
General.
- 39 -

Vertical Fin Structure

4.3.2
Vertical Fin Structure.
- 39 -

Vertical Fin Attach Fittings

4.3.3
Vertical Fin Attach Fittings
- 39 -

Rudder

4.4
Rudder.
41 -

General Rudder

4.4.1
General.
- 41 -

Maintenance Course B1/B2
ATA 50-51-53-54-55-57
Issue 4 - October 2024
- 1 -
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BOSTONAIR
Technical Training
BOSTONAIR
TECHNICAL TRAINING LIMITED
UK.147.0085
TECHNICAL TRAINING MANUAL
BOEING 737-600/-700/-800/-900

Rudder Structure

4.4.2
Rudder Structure.
- 41 -

Wings

5
Wings
42 -

General Wings

5.1
General
42 -

Wing Boxes

5.1.1
Wing Boxes.
42 -

Center Wing Box

5.1.2
Center Wing Box.
42 -

Center Wing Box Structure

5.2
Center Wing Box.
44 -

General Center Wing Box

5.2.1
General.
- 44 -

Center Wing Box Structure Details

5.2.2
Center Wing Box Structure.
. 44 -

Wing Terminal Fittings

5.2.3
Wing Terminal Fittings.
44 -

Wing Box to Center Wing Box Connection

5.2.4
Wing Box to Center Wing Box Connection.
44 -

Wing Spars

5.3
Wing Spars.
46 -

General Wing Spars

5.3.1
General.
46 -

Wing Front Spars

5.3.2
Wing Front Spars.
46 -

Wing Rear Spars

5.3.3
Wing Rear Spars.
46 -

Wing Ribs

5.4
Wing Ribs.
48 -

General Wing Ribs

5.4.1
General.
48 -

Standard Ribs

5.4.2
Standard Ribs
- 48 -

Special Ribs

5.4.3
Special Ribs.
48 -

Rib Access Openings

5.4.4
Rib Access Openings.
48 -

Wing Stringers

5.5
Wing Stringers
50 -

General Wing Stringers

5.5.1
General.
- 50 -

Landing Gear Support Beams

5.6
Landing Gear Support Beams.
- 51 -

General Landing Gear Support Beams

5.6.1
General.
51 -

Landing Gear Support Beam Structure

5.6.2
Landing Gear Support Beam Structure. .
- 51

Flight Control Surfaces

5.7
Flight control surfaces.
53

General Flight Control Surfaces

5.7.1
General.
- 53 -

Ailerons

5.7.2
Ailerons
- 53 -

Trailing Edge Flaps

5.7.3
Trailing Edge Flaps.
- 53 -

Leading Edge Flaps

5.7.4
Leading Edge Flaps.
53 -

Leading Edge Slats

5.7.5
Leading Edge Slats.
53 -

Spoilers

5.7.6
Spoilers.
.53 -

Ailerons Details

5.8
Ailerons ....
54 -

General Ailerons

5.8.1
General.
54 -

Ailerons Structure

5.8.2
Ailerons.
54 -

Aileron Balance Tabs

5.8.3
Aileron Balance Tabs.
54 -

Spoilers Details

5.9
Spoilers.
- 55 -

General Spoilers

5.9.1
General.
55 -

Ground Spoilers

5.9.2
Ground Spoilers.
55 -

Flight Spoilers

5.9.3
Flight Spoilers.
55 -

Maintenance Course B1/B2
ATA 50-51-53-54-55-57
Issue 4 - October 2024
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Technical Training
BOSTONAIR
TECHNICAL TRAINING LIMITED
UK.147.0085
TECHNICAL TRAINING MANUAL
BOEING 737-600/-700/-800/-900

LIST OF FIGURES

• Figure 1: 737 Structures
  - 6 -
• Figure 2: Structural classification diagram
  · 8 -
• Figure 3: Primary and secondary structures
  - 9 -
• Figure 4: Composites
  11 -
• Figure 5: Fuselage sections
  14 -
• Figure 6: Nose radome.
  15 -
• Figure 7: Main frame
  17 -
• Figure 8: Cockpit section
  18 -
• Figure 9: Section 41
  19 -
• Figure 10: Section 43
  20 -
• Figure 11: Section 43 - wing to body fairing structure
  21 -
• Figure 12: Section 46.
  22 -
• Figure 13: Section 48 - upper section.
  23 -
• Figure 14: section 48 - lower section
  24
• Figure 15: Section 48 - bulkheads
  25 -
• Figure 16: Drains
  27 -
• Figure 17: Nacelle and pylon
  29 -
• Figure 18: Nacelle strut
  31 -
• Figure 19: Auxiliary structure
  33 -
• Figure 20: Engine attach fittings
  34
• Figure 21: Horizontal stabilizer center section
  35 -
• Figure 22: Horizontal stabilizer
  36 -
• Figure 23: Elevator
  38 -
• Figure 24: Vertical stabilizer
  39 -
• Figure 25: Vertical stabilizer
  40 -
• Figure 26: Rudder
  41 -
• Figure 27: Wing - top and bottom view
  42 -
• Figure 28: Wings
  43 -
• Figure 29: Wing box
  45 -
• Figure 30: Wing spars.
  47 -
• Figure 31: Wing ribs
  49 -
• Figure 32: Wing stringers
  .....
  50
• Figure 33: Landing gear support structure
  52 -
• Figure 34: Flight control surfaces
  - 53 -
• Figure 35: Ailerons
  54 -
• Figure 36: Spoilers
  55 -

Maintenance Course B1/B2
ATA 50-51-53-54-55-57
Issue 4 - October 2024
- 3 -BOSTONAIR
Technical Training
BOSTONAIR
TECHNICAL TRAINING LIMITED
UK.147.0085
TECHNICAL TRAINING MANUAL
BOEING 737-600/-700/-800/-900

ABBREVIATIONS AND ACRONYMS

• APU
  Auxiliary Power Unit
• BL
  Body Buttock
• CG
  Center of Gravity
• CRES
  Corrosion Resistant Steel
• LBL
  Left Buttock Line
• LDG
  Landing Gear
• MAG
  Magnet or Magnetic
• WL
  Water Line

Maintenance Course B1/B2
ATA 50-51-53-54-55-57
Issue 4 - October 2024
- 4 -BOSTONAIR
Technical Training
BOSTONAIR
TECHNICAL TRAINING LIMITED
UK.147.0085
TECHNICAL TRAINING MANUAL
BOEING 737-600/-700/-800/-900

Structures Overview

1 Structures

Introduction to Aircraft Structures

1.1 Introduction

Basic Structural Description of Aircraft

1.1.1
Basic structural description
Fuselage Section.
The fuselage is a semi-monocoque structure. Stringers and frames
reinforce the fuselage skin. The keel beam and stringers support the
fuselage longitudinally. Numerous bulkheads support loads placed on the
fuselage. Transverse floor beams further strengthen the fuselage.
Wing Center Section.
The wing center section has upper and lower skin panels, front and rear
spars, floor beams and the keel beam.
Wing Structure.
The wing is constructed with front and rear spars, ribs, stringers, and skin
panels.
Horizontal Stabilizer Structure.
The horizontal stabilizer is constructed with an auxiliary spar, front spar,
rear spar, and stringers and ribs.
Vertical Stabilizer Structure.
The vertical stabilizer is constructed with an auxiliary spar, front spar, rear
spar, and stringers and ribs.

Maintenance Course B1/B2
ATA 50-51-53-54-55-57
Issue 4 - October 2024
- 5 -BOSTONAIR
Technical Training
BOSTONAIR
TECHNICAL TRAINING LIMITED
UK.147.0085
TECHNICAL TRAINING MANUAL
BOEING 737-600/-700/-800/-900

Boeing 737-800 Components

Boeing 737-800

Wing Inspection and Navigation

49 Wing inspection
64 Starboard
81 Floor beams
82 Wing centre
86 Port main
96 Cockpit voice
107
135 Inboard flap track
162 Port twin
1 Radome with
lightning
door
50 Wing spar
navigation and
strobe lights
65 Aft strobe light
section carry-
through
97 Flight data
(ground) spoiler
163 Main
conductor strips
escape
51 Conditioned air
66 Starboard aileron
83 Centre section
98 Fin root fillet
2 Weather radar
chute/slide
risers to
67 Aileron hinge
control
integral fuel tank
structure
scanner
35 Airstairs
overhead ducting
52 Forward and min
68 Aileron tab
attachment joints
retraction jack
4 Radar scanner
37 Underfloor
cabin air
69 Outboard double-
slotted flap
84 Air conditioning
pack, port and
starboard, in
ventral fairing
beneath wing
box
89 Cabin wall
insulation
blankets
100 Rudder tandem
139 Flap screw jacks
tracking
avionics
distribution
ducting, rear
cabin air duct on
starboard side
segment, down
position
attachment main
frame
101 Fin rib structure
102 Starboard

Control and Instrument Panels

6 Rudder pedals
and carriages
91 Overhead
trimming
tailplane
8 Instrument panel,
39 Passenger
54 Hinged cowling
service units
103 Starboard
EFIS displays
oxygen bottle
panels
72 Spoiler hydraulic
jacks
92 ADF antenna
elevator
93 Cabin roof
104 Two-spar fin
trim/lighting
panels
torsion box
10 Windscreen
41 Forward
refuelling
connection
94 Overhead
122
120 Tailplane
trimming screw
jack and electric
motor
141 Flap track
fairings
170 Ventral ram air
intake to
conditioning
system heat
exchangers
windows
43 Overhead
75 Inboard (ground)
unit (APU)
171 Inboard Krueger
13 Overhead
systems control
pane
ducting
channels
77 Anti-collision
106 Static
structure
15 Captain's seat
beacon light
dischargers
145 Aileron tab
174 Intake de-icing
107 Rudder
146 Port aileron
air duct
108 Composite
147 Fixed portion of
175 Engine intake,
flattened at
lower edge
undercarriage
wheel bay
61 Leading edge de-
5
control
dischargers
176 CFM56-7
18 Nosewheel doors
62 Slat guide rails
compartments,
port and
151 Port navigation
retracting
113 Port elevator
128 Rear cabin
and strobe lights
152 Port leading
177 Engine fan
casing
20 Torque scissor
links
passenger
seating
edge slat
segments,
21 Hydraulic
115 Port trimming
129 Cabin window
extended
pivot mounting
tailplane torsion
frame and
stringer
154 Slat guide rails
155 Slat screw jacks
156 Wing rib
179 Thrust reverser
25 Observer's
131 Mid cabin
structure
26 Forward toilet
"182
[150
158 Wing bottom
28 Starboard
skin/stringer
panel
182 Translating
service door
159 Access
cowling, reverser
units
mounting
160 Two-spar wing
compartment
section structure
134 Port inboard
31 Cabin attendant's
folding seat
119 Fin mounting
bulkhead
double-slotted
flap segment
161 Leading edge de-
icing air duct
184 Pylon attachment
joints
35

Aircraft Sections and Systems

Figure 1: 737 Structures
panels
42 Cabin wall trim
74 Inboard flap
12 Cockpit eyebrow
panelling
segment
95 Rear underfloor
freight hold door
121 Auxiliary power
122 Shock absorbing
tailskid
143 Outboard double-
slotted flap
segment
144 Port flap down
position
flap, extended
14 Co-Pilot's seat
44 Cabin floor with
continuous seat
rails
60 Starboard
78 Overwing
45 lower UHF
emergency exits,
two per side
rudder skin
trailing edge
17 Nose
46 Six abreast
55
109 Elevator hinge
126 Cabin attendant's
148 Static
icing air duct
110 Tail navigation
light
150 Wing tip fairing
19 Twin nosewheels,
forward
63 Slat screw jacks,
torque shaft
driven via central
hydraulic motor
111 APU exhaust
134
112 Elevator tab
starboard
steering jacks
22 Nosewheel leg
tailplane
panels
153 Telescopic de-
icing air ducts
on starboard
side
24 Cockpit bulkhead
130
structure
cascades
folding seat
175
148
seating
157 Port wing
integral fuel tank
181 Fan air (cold
stream) exhaust
duct
29 Forward galley
117 Tailplane pivot
132 Fuselage lower
lobe skin
manholes
cascade opening
30 Closet
118 Tailplane centre-
133 Wing root trailing
edge fillet
torsion box
structure
183 Core engine (hot
stream) exhaust
duct
mechanism
equipment bay
90 Rear spar
hydraulic
actuators
140 Flap guide rails,
carriages and
hinge linkages
166 Leading edge
ribs
5 Front pressure
bulkhead
38 Fuselage lower
lobe frame and
stringer
structure
53 Starboard engine
nacelle
71 Outboard (flight)
spoilers
passenger
112
167 Engine bleed air
duct to
conditioning
system
9 Instrument panel
shroud
structure
56 Pressure
115
169 Leading edge
wing root fillet
wipers
underfloor freight
hold door
57 Starboard wing
integral fuel tank,
total fuel capacity
26.035 lit
(5,729 Imp gal)
spoiler
58 Fuel venting
76 Upper UHF
antenna
105 Rudder horn
balance
123 Rear pressure
bulkhead
172 Nacelle strake
173 Nacelle pylon
16 Flight bag/
document
stowage
antenna
leading edge slat
segments,
extended
folding seat
127 Rear toilet
149 Rear strobe light
turbofan engine
with FADEC
control
passengers in
mixed class
arrangement
114 Elevator horn
178 Side mounted
accessory
equipment
gearbox, oil tank
48 Conditioned-air
distribution
system
116 Two-spar
130 Aft fuselage
23 Dual pitot heads
box structure
180 Engine turbine
section
compartment
27 Cockpit door
passenger
seating, 184
passengers in all
economy layout
or 160
59 Overwing filler
cap
124 Rear galley unit
125 Rear cabin door,
port and
starboard
taxiing lights
40 Floor beam
55 Nacelle pylon
73 Single slotted
portion of flap
(thrust gate
segment)
11 Windscreen
baggage lockers
142 Port outboard
(flight) spoiler
panels
7 Control yoke
36 Folding handrail
80 Wing front spar
attachment main
frame
87 Central flap drive
hydraulic motor
recorder
103
137 Main
undercarriage
leg strut
88 Pressure floor
above wheel bay
99 Fin spar
138 Hydraulic
164 Folding side stay
165 Inboard
3 ILS glideslope
32 Entry lobby
33 Forward entry
light
79 Fuselage centre
section frame
and stringer
structure
undercarriage
wheel bay
recorder
136 Port inboard
mainwheels
34 Door mounted
bulkhead
undercarriage
mounting beam
machined wing
ribs
10
70 Flap guide rails
85 Wing root joint
strap
168 Landing and
Mike Badtacke
47 Cabin window
panels
balance
141
144
conditioned-air
distribution

Maintenance Course B1/B2
ATA 50-51-53-54-55-57
Issue 4 - October 2024
- 6 -