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B737NG/00/103

Airplane General -900ER

Boeing 737-900ER

Airplane General
Training manual
For training purposes only
LEVEL 1

ATA 00

page 1
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B737NG/00/103
Airplane General -900ER

Training manual

This publication was created by Sabena technics training department,


Brussels-Belgium, following ATA 104 specifications.
The information in this publication is furnished for informational and training
use only, and is subject to change without notice.
Sabena technics training assumes no responsibility for any errors or
inaccuracies that may appear in this publication.
No part of this publication may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission
of Sabena technics training.

Contact address for


course registrations
course schedule information
Sabena technics training
training@sabenatechnics.com

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Airplane General -900ER

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Airplane General -900ER

Table of Contents
1. Range.....................................................................................................6
2. DIMENSIONS...........................................................................................8
2.1. General..................................................................................................8
2.2. Fuselage Dimensions.............................................................................10
2.3. Wing Reference Dimensions.................................................................12
2.4. Vertical Stabilizer Reference Dimensions................................................14
2.5. Horizontal Stabilizer Reference Dimensions...........................................16
3. AFT Flat Pressure Bulkhead..........................................................18
4. ZONE DIAGRAM....................................................................................20
4.1. General................................................................................................20
5. GROUND SERVICE POINTS....................................................................22
5.1. General................................................................................................22

8. FUSELAGE..............................................................................................30
8.1. Internal Structure..................................................................................30
8.2. Cross Section .......................................................................................32
8.3. Forward Bulkhead & Cargo Compartment ...........................................34
8.4. AFT Pressure Bulkhead .........................................................................36
9. WINGS . .................................................................................................38
9. General ..................................................................................................38
9.2. Internal Structure..................................................................................40
9.3. Winglet ...............................................................................................42
9.4. Ribs & Spars..........................................................................................44
10. STABILIZERS.........................................................................................46
10.1. General..............................................................................................46

6. ANTENNA LOCATIONS..........................................................................24
6.1. Antenna Location.................................................................................24
7. PRIMARY AND SECONDARY structures..........................................26
7.1. General................................................................................................26
8. COMPOSITES.........................................................................................28
8.1. General................................................................................................28

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List of Illustrations
737 Range.............................................................................................................................. 7
AFT FLAT PRESSURE BULKHEAD.............................................................................................. 19
AFT PRESSURE BULKHEAD...................................................................................................... 37
ANTENNA LOCATIONS............................................................................................................ 25
COMPOSITES.......................................................................................................................... 29
CROSS SECTION..................................................................................................................... 33
FORWARD BULKHEAD & CARGO COMPARTMENT................................................................. 35
Fuselage Dimensions.......................................................................................................... 11
GROUND SERVICE POINTS...................................................................................................... 23
HORIZONTAL STABILIZER REFERENCE DIMENSIONS................................................................. 17
INTERNAL STRUCTURE............................................................................................................ 31
INTERNAL STRUCTURE............................................................................................................ 41
PRIMARY AND SECONDARY structures.............................................................................. 27
RIBS & SPARS.......................................................................................................................... 45
STABILIZERS............................................................................................................................ 47
Structure & Dimensions...................................................................................................... 9
VERTICAL STABILIZER REFERENCE DIMENSIONS...................................................................... 15
WINGLET................................................................................................................................ 43
WING REFERENCE DIMENSIONS.............................................................................................. 13
WINGS.................................................................................................................................... 39
ZONE DIAGRAM..................................................................................................................... 21

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Abbreviations and Acronyms


A/T
ACMS
ACP
ADF
ADIRU
AGCU
AM
AMM
APB
APU
ATC
BL
BPCU
BTB
CDS
CDU
CG
comm
CPS
DEU
DFCS
DME
ECU
EE
EEC
EGT
ELT
EMDP
EPC
ext
FDAU
FLT
FMC
FMCS
FQIS
GCB
GCU
GRD
HF
IDG
ILS
inv
INOP
LRRA
LRU

Auto Throttle System


Airplane Condition Monitoring System
Audio Control Panel
Automatic Direction Finder
Air Data Inertial Reference Unit
APU Generator Control Unit
Ammeter
Aircraft Maintenance Manual
APU Power Breaker
Auxiliary Power Unit
Air Traffic Control
Buttock Line
Bus Power Control Unit
Bus Tie Breaker
Comon Display System
Control Display Unit
Center of Gravity
Communication
Cycle Per Sec
Display Electronic Unit
Digital Flight Control System
Distance Measuring Equipment
Electronic Control Unit
Electronic Equipment
Electronic Engine Control
Exhaust Gas Temperature
Emergency Locator Transmitter
Electric Motor Driven Pump
External Power Contactor
External
Flight Data Acquisition Unit
Flight
Flight Management Computer
Flight Management Computer System
Fuel Quantity Indication System
Generator Control Breaker
Generator Control Unit
Ground
High Frequency
Integrated Drive Generator
Instrument Landing System
Inverter
Inoperation
Low range radio altimeter
Line replaceable unit

LSK
MLG
MIC
NDB
NLG
OFST
P/B
PDL
PDP
pwr
R/T
RTU
RCCB
SCU
SPCU
SPKR
SPU
STA
stby.
SWPM
TCAS
TCI
TRU
VHF
VOR
WDM
WL
WXR

Line Select Keys


Main Landing Gear
Microphone
Non Direction Beacon
Nose Landing Gear
Offeset
Pushbutton
Portable Data Loader
Power Distribution Panel
Power
Radio Transmit
Receiver Transmitter Unit
Remote Control Ciruit Breaker
start converter unit
Standby Power Control Unit
Speaker
Start Power Unit
Station
Standby
Standard Wiring Practices Manual
Traffic Alert & Collision Avoidance System
Time Change Item
Transformer Rectifier Unit
Very High Frequency
VHF Omni Range
Wiring Diagram Manual
Water Line
Weather Radar

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1. Range
General Information
The 737 is a two-engine airplane. It is for short to medium range flights.
Features
There are many new features. These new features increase the airplane
payload, range and and service ceiling.

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Airplane General -900ER

737 Range
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2. DIMENSIONS
2.1. General
These are the general dimensions of the airplane.
NOTE: The wing span dimension shows with winglet installation. Without
winglet installation, the wing span is 112 feet 7 inches (32.3 meters).

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Structure & Dimensions


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2.2. Fuselage Dimensions


General
Dimensions give locations on the fuselage. The scale for each dimension is
inches. You use these dimensions to find components on the fuselage:
- Body station line
- Body buttock line
- Water line.
The body station line (STA) is a horizontal dimension. It starts at station line
zero. You measure the body station line from a vertical reference plane that is
forward of the airplane.
The body buttock line (BL) is a lateral dimension. You measure the buttock line
to the left or right of the airplane center line.
The water line (WL) is a height dimension. You measure the water line from a
horizontal reference plane below the airplane.

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Airplane General -900ER

Fuselage Dimensions
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2.3. Wing Reference Dimensions


The wing has two reference dimensions. These reference dimensions give wing
Locations in inches. Measure each location from buttock line 0. These are the
wing reference dimensions:
- Wing station
- Wing buttock line.
You measure the wing station perpendicular to the wing leading edge.
You measure the wing buttock line parallel to the buttock Line.
For more information, see the maintenance manual and the maintenance
planning data document.

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WING REFERENCE DIMENSIONS


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2.4. Vertical Stabilizer Reference Dimensions


The vertical stabilizer has four reference dimensions. These reference
dimensions give vertical stabilizer locations in inches. These are the vertical
stabilizer reference dimensions:
- Vertical stabilizer station
- Vertical stabilizer leading edge station
- Rudder station
- Vertical stabilizer waterline.
Measure the vertical stabilizer station perpendicular to the vertical stabilizer
rear spar. Vertical stabilizer station 0 starts at the body crown line.
Measure the vertical stabilizer leading edge station perpendicular to the
vertical stabilizer leading edge.
Vertical stabilizer leading edge station 0 starts at the body crown line.
Measure the rudder station perpendicular to the rudder hinge centerline.
Rudder station 0 starts at the body crown line.
Measure the vertical stabilizer waterline parallel to the body waterline.
For more information, refer to the maintenance manual and the maintenance
planning data document.

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Airplane General -900ER

VERTICAL STABILIZER REFERENCE DIMENSIONS


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Airplane General -900ER

2.5. Horizontal Stabilizer Reference Dimensions


The horizontal stabilizer has three reference dimensions. These reference
dimensions give horizontal stabilizer locations in inches. Measure each location
from buttock line O. These are the horizontal stabilizer reference dimensions:
- Stabilizer station
- Stabilizer leading edge station
- Elevator station.
Measure stabilizer stations perpendicular to the horizontal stabilizer rear spar.
Measure stabilizer leading edge stations perpendicular to the horizontal
stabilizer leading edge.
Measure elevator stations perpendicular to the elevator hinge centerline.
For more information, refer to the maintenance manual and the maintenance
planning data document.

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Airplane General -900ER

HORIZONTAL STABILIZER REFERENCE DIMENSIONS


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Airplane General -900ER

3. AFT Flat Pressure Bulkhead


General Description
The flat bulkhead design lets you have greater galley capability and increased
seating.
Location
The bulkhead is at station 1042.

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Airplane General -900ER

AFT FLAT PRESSURE BULKHEAD


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4. ZONE DIAGRAM
4.1. General
The airplane has eight major zones to help you find and identify the airplane
components and parts. The major zones are divided into subzones and the
subzones into zones. These are the major zones:
- 100 - lower half of the fuselage
- 200 - upper half of the fuselage
- 300 - empennage
- 400 - powerplant and nacelle struts
- 500 - left wing
- 600 - right wing
- 700 - landing gear and landing gear doors
- 800 - doors.

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Airplane General -900ER

ZONE DIAGRAM
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Airplane General -900ER

5. GROUND SERVICE POINTS


5.1. General
The diagram shows the normal servicing points. These service points let you
do these tasks:
- Supply electrical power
- Add or remove fuel
- Supply conditioned air
- Supply pressurized air
- Service the lavatory
- Service the potable water system
- Add the crew oxygen
- Add oil to the engine, IDG, and APU
- Service the hydraulic system
- Service the brake accumulator.

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GROUND SERVICE POINTS


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6. ANTENNA LOCATIONS
6.1. Antenna Location
These are the communication and navigation system antennas:
- Weather Radar
- Traffic alert and collision avoidance system (TCAS)
- Air traffic control (ATC)
- Global positioning system (GPS)
- Very high frequency (VHF) communication
- Automatic direction finder (ADF)
- Satellite communication (SATCOM)
- VHF omni range (VOR)/Localizer (LOC)
- Marker beacon
- Radio altimeter
- Distance measuring equipment (DME)
- Localizer
- Glideslope.

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ANTENNA LOCATIONS
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7. PRIMARY AND SECONDARY structures


7.1. General
These are the two types of airplane structures:
- Primary
- Secondary.
Primary Structures
A primary structure transmits flight, ground or pressure Loads. These are the
primary structures:
- Skin
- Door
- Landing Gear.
Secondary Structures
A secondary structure transmits onLy air or inertial loads created on or in the
secondary structure. Most secondary structures are important to aerodynamic
performance of the airplane. Secondary structure includes the skin and
structure of doors that are not primary structure. These are also secondary
structures:
- Radome
- Airstairs
- Leading edges
- Stabilizer tips
- Fairings
- Cowlings.

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PRIMARY AND SECONDARY structures


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8. COMPOSITES
8.1. General
Some airplane structure is made of composite materials that are resistant to
damage and corrosion and decrease airplane weight. Composite materials
are layers of strong fibers of carbon or fiberglass in a mixture of plastic resin.
Components made of composite materials use laminations or mix layers of
composite materials with a honeycomb core to make a sandwich construction.
Composite Materials
The airplane structure uses composite materials for their high strength
to weight ratio. Weight reduction is made by use of carbon fiber and
advanced fiber composite materials. Composite materials also provide these
improvements:
- Fatigue protection
- Corrosion protection
- Sonic Resistance
- Aerodynamic surfaces.

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Carbon Fiber
Carbon fiber is used for these primary movable surfaces:
- Ailerons
- Elevators
- Rudder
- Spoilers
- Trailing edge flaps.
Carbon reinforced fiberglass hybrids are used for secondary fairing structures.
Corrosion Protection
Special protective systems are used to prevent galvanic corrosion of aluminum
components in contact with carbon materials. Each aluminum component is
anodized, primed and enameled. An isolating sealant is on all contact
surfaces at assembly and on all fasteners. Corrosion resistant steel or titanium
is used with carbon fiber components.

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COMPOSITES
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8. FUSELAGE
8.1. Internal Structure
Fuselage Components
The fuselage is a pressurized semi-monocoque structure made primarily of
aluminum alloys.
Bulkheads
Pressure bulkheads at the forward and aft ends of the fuselage form a
pressure vessel. Bulkheads distribute major loads into the fuselage at these
locations:
- Landing gear supports
- Wing Spars
- VerticaL stabiLizer spars
- Horizontal stabilizer hinge attach points.
Bulkheads aLso function as part of the pressure vessel at these locations:
- Forward fuselage
- Aft fuselage
- Wheel Well
- Other pressure closeouts.

Strinqers
Stringers are long structures that go from the nose to the tail of the fuselage.
Most of them are made from aluminum. Stringers transmit axial loads from
body bending and compression Loads caused by skin diagonal tension.
Floor Beams
Floor beams support the cabin floor and seat tracks. Most of the floor beams
go laterally from one side to the other in the fuselage. The floor beams above
the wing support area go longitudinally from front to rear because of wing
travel. ALL of the floor beams are made of aluminum.
Keel Beam
The keel beam keeps the ability of the fuselage to bend where the wing and
wheel well are. It is of a box beam design and transmits a large compression
Load because of body bending movement. It has a below wing section and a
wheel well section.
Fuselaqe Auxiliary Structures
These auxiliary structures attach to the fuselage:
- Nose radome
- Wing to body fairings
- Tail cone.

Frames
Frames are circular structures below the skin of the fuselage. These are the
frame functions:
- Hold the shape of the fuselage
- Transmit tension loads due to pressurization
- React to bending due to passenger and cargo deck loading
- Supply a load path for floor beams
- Supply a load path for overhead bin loads into the skin.
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INTERNAL STRUCTURE
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8.2. Cross Section


Stringers are attached to the frames. The stringer at the top of the frame is
stringer number one. ALL other stringers are numbered in sequence down
the Left and right side of the frame. The typicaL fuseLage cross section has an
upper and lower lobe that aLign at the passenger floor Level. The ends of the
floor beams are attached to the sides of the frames between the Lobes.

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Airplane General -900ER

CROSS SECTION
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8.3. Forward Bulkhead & Cargo Compartment


The forward pressure bulkhead is Located at the front end of the fuseLage
behind the radome. Frames, stringers, and floor beams are located in the
fuselage structure.

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FORWARD BULKHEAD & CARGO COMPARTMENT


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8.4. AFT Pressure Bulkhead


Most airplanes have the rounded aft pressure bulkhead. Some airplanes have
the flat aft pressure bulkhead. The fLat bulkhead provides more interior room
in the fuselage.

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Airplane General -900ER

AFT PRESSURE BULKHEAD


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9. WINGS
9. General
The wing is a cantilevered structure. The basic wing structure is aluminum. The
wing has these features:
- Fuel tanks
- Fuel system components
- Attach points for the engine strut, landing gear and flight controls.
Fuel tank access panels on the bottom of the wing skin allow access to fuel
tanks. Different wingtip or winglets are installed according to customer
requests.

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WINGS
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9.2. Internal Structure


General
The wing has spars and ribs. The wing has a front spar and a rear spar. The
front spar transmits most of the load from the wing to the fuselage. The
front spar is also the mounting structure for the leading edge flaps and slats.
The rear spar also transmits loads to the fuselage but also is the mounting
structure for the flaps and ailerons.
The ribs are numbered from 1 to 27. Rib number 1 is the most inboard rib on
the wing and is also called the side of body rib. Rib 5 is the divider between
the center and main fuel tanks. Rib 22 is the divider between the main tank
and the surge tank. Rib 25 is the end of the surge tank.

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INTERNAL STRUCTURE
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9.3. Winglet
General
The winglets are made of graphite spars, aluminum ribs and aluminum skins.
The forward position, aft position and strobe lights are included into the
structure.

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WINGLET
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9.4. Ribs & Spars


General
The wings are assembled in vertical jigs. The spars and ribs are connected first
and then the skins are attached.

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RIBS & SPARS


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10. STABILIZERS
10.1. General
The horizontal and vertical stabilizers are assembled with spars and ribs. The
elevators and rudder are assembled with graphite composite materials. The
vertical stabilizer has a dorsal fin to help keep the airplane stable.

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STABILIZERS
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