Cascade Aviation Services, Inc.

Document Identification: Document No.

Weight and Balance Compliance 05CAS469-D20

Title:
Eyebrow Window Replacement for Boeing 737 Series Aircraft

Project No.: Customer:

ST01630SE TBD

Revision Date
NEW 8/24/05
A 9/19/05
B 5/1/06
C 8/9/07

Prepared by:

E. Graudins Date: 8/24/05

original revision signed by

Approved by:

P. Kingswell Date: 8/24/05

original revision signed by
 Cascade Aviation Services Inc.

REVISION PAGE
Revision Description Date Approval

NEW Original Release. 8/24/05 See Cover

Prepared:
A Added W&B manual references for other 737 9/19/05 E. Graudins
models Approved:
P. Kingswell
Prepared:
B Corrected Classic 737 moment arms in Tables 5/1/06 E. Graudins
1 and 3. Approved:
P. Vallins
Prepared:
C Added weight data for alternate installation 8/9/07 E. Graudins
configurations, see Tables 4 and 5.
Approved:
B. Norman

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LIST OF ACTIVE PAGES

Page Revision Added Pages
Section Number Level Page Revision Page Revision Page Revision

1 C 10 A
2 C 11 A
3 C 12 A
4 A 13 A
5 C 14 A
6 C
7 C
8 C
9 New

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TABLE OF CONTENTS

TITLE PAGE....................................................................................................................................................... 1

REVISION PAGE................................................................................................................................................ 2

LIST OF ACTIVE PAGES.................................................................................................................................. 3

TABLE OF CONTENTS..................................................................................................................................... 4

REFERENCES..................................................................................................................................................... 5

INTRODUCTION................................................................................................................................................ 5

COMPLIANCE WITH APPLICABLE FAA RULES ........................................................................................ 5

SUMMARY OF WEIGHT CHANGES .............................................................................................................. 6

FIGURE 1: WEIGHT AND CENTER OF GRAVITY ENVELOPE (737-700) ................................................ 8

FIGURE 2: CENTER OF GRAVITY LIMITS (737-300) .................................................................................. 9

FIGURE 3: CENTER OF GRAVITY LIMITS (737-400) .................................................................................10

FIGURE 4: CENTER OF GRAVITY LIMITS (737-500) .................................................................................11

FIGURE 5: CENTER OF GRAVITY LIMITS (737-800) .................................................................................12

FIGURE 6: CENTER OF GRAVITY LIMITS (737-900) .................................................................................13

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REFERENCES

Cascade Aviation Services Drawings

-05CAS469201 737 Eyebrow Window Replacement, Installation Instructions
-05CAS469202 Insulation Upgrade Installation Instructions
-05CAS469203 737 Eyebrow Window Replacement, Installation Instructions

Boeing Documents
D6-15066-4 Boeing 737-300 Weight and Balance Control and Loading Manual
D043A540-HAP1 Boeing 737-400 Weight and Balance Control and Loading Manual
D6-15066-6 Boeing 737-500 Weight and Balance Control and Loading Manual
D043A570-AWW1 Boeing 737-700 Weight and Balance Control and Loading Manual
D043A580-ILF2 Boeing 737-800 Weight and Balance Control and Loading Manual
D043A590-ASA1 Boeing 737-900 Weight and Balance Control and Loading Manual

INTRODUCTION

This document summarizes the weight and balance changes to a Boeing 737 series aircraft for the
replacement of the OEM eyebrow windows with window blanks made by Cascade Aviation.

Balance Arm Stations determined from Flight Station of object CG.

COMPLIANCE WITH APPLICABLE FEDERAL AVIATION ADMINISTRATION RULES

This document demonstrates compliance with CFRs 25.23(a) amendment 25-0, 25.25 amendment 25-63,
and 25.27 amendment 25-0.

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SUMMARY OF WEIGHT CHANGES

The Station Locations of cockpit windows #4 and #5 are the same for all 737 series aircraft. The
corresponding Balance Arms for the windows of each particular aircraft model are shown in Table 1
(both classic and next-generation 737s). The detailed Weight and Balance change to one 737 model
resulting from the installation is shown in Table 2. Tables 3, 4, and 5 summarize the overall W&B change
for all models of 737 for each of the three installation kit configurations.

TABLE 1: STA/Arm cross reference

Aircraft Window #4 Window #5
Type STA Balance Arm STA Balance Arm
737-100 219.0 219.0 230.0 230.0
737-200 219.0 196.0 230.0 207.0
737-300, -700 219.0 139.0 230.0 150.0
737-400 219.0 67.0 230.0 78.0
737-500, -600 219.0 193.0 230.0 204.0
737-800 219.0 21.0 230.0 32.0
737-900 219.0 -41.0 230.0 -30.0

TABLE 2: Example window removals and additions for 737-700 (using 05CAS469201 install)
Window P/N Weight Arm Moment
(lbs) (in) (in-lbs)
Old RH window 4 5-89357-34 -7.3 139.0 -1014.7
Old RH window 5 5-89358-42 -4.4 150.0 -660.0
Old LH window 4 5-89357-33 -7.3 139.0 -1014.7
Old LH window 5 5-89358-41 -4.4 150.0 -660.0
New RH window 4 05CAS469401-2 6.5 139.0 903.5
New RH window 5 05CAS469402-2 4.1 150.0 615.0
New LH window 4 05CAS469401-1 6.5 139.0 903.5
New LH window 5 05CAS469402-1 4.1 150.0 615.0
TOTAL: -2.2 -312.4

TABLE 3: Weight & Balance change to 737 aircraft (05CAS469201 installation)

Aircraft Weight Change Moment Change
Type (lbs) (in-lbs)
737-100 -2.2 -488.4
737-200 -2.2 -437.8
737-300, -700 -2.2 -312.4
737-400 -2.2 -154.0
737-500, -600 -2.2 -431.2
737-800 -2.2 -52.8
737-900 -2.2 83.6

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TABLE 4: Weight & Balance change to 737 aircraft (05CAS469201 and 05CAS469202
installations)
Aircraft Weight Change Moment Change
Type (lbs) (in-lbs)
737-100 -1.1 -242.0
737-200 -1.1 -216.7
737-300, -700 -1.1 -154.0
737-400 -1.1 -74.8
737-500, -600 -1.1 -213.4
737-800 -1.1 -24.2
737-900 -1.1 44.0

TABLE 5: Weight & Balance change to 737 aircraft (05CAS469203 installation)

Aircraft Weight Change Moment Change
Type (lbs) (in-lbs)
737-100 -2.2 -489.0
737-200 -2.2 -438.4
737-300, -700 -2.2 -313.0
737-400 -2.2 -154.6
737-500, -600 -2.2 -431.8
737-800 -2.2 -53.4
737-900 -2.2 83.0

All models of 737 aircraft have the same Mean Aerodynamic Cord length and MAC Leading Edge
location.

L.E. MAC = 627.06” = Upper constant MAC = 155.81” = lower constant

Arm – 627.06
C.G. = 100 *  = % MAC
155.81

The W&B change to a representative 737-700 aircraft (ref Table 2) is shown in Tables 6 and 7. The
acceptable weights and CG locations of a 737-700 are defined in the Boeing Weight and Balance
Manual, see manual D043A570-AWW1 (chart reproduced as Figure 1 on page 9 of this document).
The CG location (in %MAC) shifts less than 0.01%. Therefore, this very small change will not shift any
737 minor model aircraft out of the acceptable W&B range. Weighing the aircraft after the
modification is not necessary. It is the airline’s responsibility to verify that each specific aircraft remains
within the operation limits defined by the OEM weigh and balance manual. CAS has provided the
necessary weight and moment changes to allow the airline to update their documentation.

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TABLE 6
PRE-MOD WEIGHT AND MOMENT
Aircraft Serial Weight Arm Moment %MAC
Tail # # (lbs) (in) (in-lb)
N738AL 28499 83,885.9 657.19 55,128,894.34 19.34

TABLE 7
POST-MOD WEIGHT AND MOMENT
Aircraft Serial Weight Arm Moment %MAC
Tail # # (lbs) (in) (in-lb)
N738AL 28499 83,883.7 657.20 55,128,581.94 19.35

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FIGURE 1: WEIGHT AND CENTER OF GRAVITY ENVELOPE (737-700)

From page 2 of section 1-02-030 in Boeing W&B Manual D043A570-AWW1.

Sample aircraft’s
CG location

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FIGURE 2: CENTER OF GRAVITY LIMITS (737-300)

From Boeing W&B Manual D6-15066-4.

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FIGURE 3: CENTER OF GRAVITY LIMITS (737-400)

From Boeing W&B Manual D043A540-HAP1.

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FIGURE 4: CENTER OF GRAVITY LIMITS (737-500)

From Boeing W&B Manual D6-15066-6.

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FIGURE 5: CENTER OF GRAVITY LIMITS (737-800)

From Boeing W&B Manual D043A580-ILF2.

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FIGURE 6: CENTER OF GRAVITY LIMITS (737-900)

From Boeing W&B Manual D043A590-ASA1.

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