B737NG/50/301

Structure

technical training

Boeing B737-600/700/800/900

Structure
Training manual
page 1
For training purposes only
15 - 04 - 2009
LEVEL 3
50-00-00 Rev : 2.0
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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

trainingservices@sabenatechnics.com

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List of Effective Pages.

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Table of Contents.
1. STRUCTURES (ATA 51).............................................................................6
1.1. Dimensions.............................................................................................6
1.2. Airplane Jack Points................................................................................8
1.3. Composite Materials.............................................................................10
1.4. Nose Radome.......................................................................................12
1.5. Major Zones.........................................................................................14

2. FUSELAGE (ATA 53)...............................................................................18

2.1. Introduction..........................................................................................18

3. NACELLES AND PYLONS (ATA 54)........................................................22

4. STABILIZERS (ATA 55)............................................................................24

4.1. Horizontal Stabilizer..............................................................................24
4.2. Vertical Stabilizer...................................................................................26

5. WINDOWS (ATA 56)..............................................................................28

5.1. Introduction..........................................................................................28
5.2. Window n°1.........................................................................................30
5.3. Control Cabin Sliding Windows - N°2 Openable Window......................34
5.4. Control Cabin Fixed Window - Window n° 3........................................36
5.5. Control Cabin Fixed Windows - N°4 and 5 Windows............................38
5.6. Passenger Cabin Windows Installation.................................................40

6. WINGS (ATA 57).....................................................................................42

6.1. Top View...............................................................................................42
6.2. Bottom View.........................................................................................44

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List of Illustrations. Abbreviations and Acronyms

737-700 — DIMENSIONS.......................................................................................................... 6 BL Buttock Line
737-800 — DIMENSIONS.......................................................................................................... 7 LBL Left Buttock Line
CFM56-7................................................................................................................................ 22
COMPOSITE MATERIALS......................................................................................................... 11 MPD Maintenance Planning Data Document
ENGINE AND NACELLE STATION DIAGRAM............................................................................. 22 RBL Right Buttock Line
FLIGHT COMPARTMENT WINDOWS........................................................................................ 29 sta Station
FUSELAGE............................................................................................................................... 19 WL Water Line
FUSELAGE CROSS-SECTION DIAGRAM................................................................................... 21
FUSELAGE STATION DIAGRAM................................................................................................ 20
GLASS COCKPIT WINDOW CROSS SECTION OF EDGE SHOWING VINYL INTERLAYER CRACKING
.............................................................................................................................................. 32
HORIZONTAL STABILIZER......................................................................................................... 25
JACK POINT LOCATIONS........................................................................................................... 9
MAJOR ZONE 300 - EMPENNAGE AND BODY SECTION 48..................................................... 17
MAJOR ZONES........................................................................................................................ 15
NACELLES - PYLONS............................................................................................................... 23
NOSE RADOME...................................................................................................................... 13
PASSENGER CABIN WINDOWS INSTALLATION........................................................................ 41
VERTICAL STABILIZER.............................................................................................................. 27
WINDOW N°1......................................................................................................................... 31
WINDOW N°1 DELAMINATION LIMITS.................................................................................... 33
WINDOW N°1 RETAINING BOLT TORQUE SEQUENCE.............................................................. 33
WINDOW N°2INSTALLATION................................................................................................... 35
WINDOW N° 3 INSTALLATION................................................................................................. 37
WINDOW N°4 AND N°5.......................................................................................................... 39
WINDOWS.............................................................................................................................. 28
WINGS - BOTTOM VIEW......................................................................................................... 45
WINGS - TOP VIEW................................................................................................................. 43

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1. STRUCTURES (ATA 51).

1.1. Dimensions.
These are the general dimensions of the airplane.

737-700 — DIMENSIONS

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737-800 — DIMENSIONS

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1.2. Airplane Jack Points.

The airplane has three main jack points and four auxiliary jack points.

- The main jack points are the wing jack points A and B, and aft body
jack point C.
- The four auxiliary jack points have one stabilizing and three landing
gear axle jack points.

- The stabilizing jack point is the forward body jack point D,

- The three landing gear axle jack points are shown in figure.

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JACK POINT LOCATIONS

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1.3. Composite Materials.

Some airplane structure and parts are composite materials.
These are some advantages of composite materials :

- High strength,
- Corrosion resistant,
- Increased fatigue life
- Light weight.

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COMPOSITE MATERIALS

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1.4. Nose Radome.

The nose radome is an aerodynamic fairing on the front of the fuselage.
Most of the material in the radome is fiberglass.

The radome area has navigation and weather radar antennas.

Lightning diverter strips prevent damage to these antennas and the equipment
they connect to. The lightning diverter strips decrease lightning energy and
transmit it to the airframe.

See the navigation chapter for more information on the navigation and
weather radar antennas. (CHAPTER 34)

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NOSE RADOME

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1.5. Major Zones.

The 737 airplane is divided into 8 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.

The zones are numbered in the sequence that follows :

- Fuselage : front to back and away from the floorline,

- Wings : inboard to outboard and front to back,
- Horizontal Stabilizer and Elevator : inboard to outboard and front to
back,
- Vertical Fin and Rudder : leading edge to the trailing edge of the
vertical stabilizer.

Each of the structural components, passenger compartment doors, cargo

compartment doors, landing gear doors, rudders, elevators, flaps, ailerons,
spoilers, leading edge devices, and equivalent components has a different
zone number.

A three-digit number identifies the major zones, subzones, and zones as

follows :

- Major Zone:the first digit is a number from 1 to 8 followed by two

zeroes,
- Subzone : the first digit represents the major zone, the second digit
is a number from 1 to 6 or 9, and the third digit is a zero,
- Zone : the first two digits represent the subzone number and the
third digit shows a component or group of components
that are in the subzone.

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MAJOR ZONES

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Major Zone 300 - Empennage and Body Section 48.

Subzone Zone Zone Name

330 Left Horizontal Stabilizer and Elevator

331 Left Horizontal Stabilizer - Removable Leading Edge

332 Left Horizontal Stabilizer - Front Spar to Rear Spar, Stabilizer

Station 57.93 to Stabilizer Buttock Line 249.81

333 Left Horizontal Stabilizer, Rear spar to Trailing Edge

334 Left Horizontal Stabilizer, Inboard Elevator

335 Left Horizontal Stabilizer - Tip

340 Right Horizontal Stabilizer and Elevator

341 Right Horizontal Stabilizer- Leading Edge

342 Right Horizontal Stabilizer - Front Spar to Rear Spar,

Stabilizer Station 57.93 to Stabilizer Buttock Line
249.81

343 Right Horizontal Stabilizer - Rear Spar to Trailing Edge

344 Right Horizontal Stabilizer - Inboard Elevator

345 Right Horizontal Stabilizer - Tip

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MAJOR ZONE 300 - EMPENNAGE AND BODY SECTION 48

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2. FUSELAGE (ATA 53).

2.1. Introduction.
The fuselage is a semi-monocoque structure.
Most of material in the fuselage is aluminum.

These auxiliary structures attach to the fuselage :

- Nose radome,
- Wing-to-body fairing,
- Tailcone.

These dimensions give locations on the fuselage.

The scale for each dimension is inches.

- 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.

Training Information Point.

Information on the section numbers, zone numbers, and access panel
numbers is in the maintenance planning data document (MPD).

Fuselage Station Diagram.

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FUSELAGE

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The fuselage station diagram gives you a reference system to help you find
components, features, and major fuselage structural openings in relation to a
datum plane. The datum plane is perpendicular to the fuselage centerline and
found 130.0 inches (3.302 meters) forward of the airplane nose.

Location Zones.
100 Lower Half of Fuselage
200 Upper Half of Fuselage

FUSELAGE STATION DIAGRAM

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FUSELAGE CROSS-SECTION DIAGRAM

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3. NACELLES AND PYLONS (ATA 54).

The nacelle is the fairings and the components that surround the engine. The engine and nacelle station diagram gives you the locations of the
The nacelle gives an aerodynamically smooth surface to the strut and engine. structural components and features on the engine and nacelle.
The nacelle also contains these items :
Location Zones.
- Inlet cowl, 400 Powerplants and Nacelle Struts.
- Fan cowl,
- Fan duct cowl and thrust reverser,
- Primary exhaust nozzle,
- Exhaust plug.

The pylon is the strut that attaches the engine to the wing. The strut also
contains these items :

- Fuel lines,
- Electrical lines,
- Hydraulic lines,
- Pneumatic ducts,
- Fairings,
- Fire detection/extinguish lines.

Nacelle stations and waterlines give locations on the nacelle­pylon.

The scale for nacelle stations and waterlines is inches.

The station line is a horizontal dimension. It starts at station line zero.

The water line is a height dimension. You measure the water line from a
horizontal reference plane below the nacelle-pylon.

Engine and Nacelle Station Diagram.

ENGINE AND NACELLE STATION DIAGRAM
CFM56-7

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NACELLES - PYLONS

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4. STABILIZERS (ATA 55).

4.1. Horizontal Stabilizer.

Most of material in the horizontal stabilizer is aluminum.
The elevator is graphite composite.

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 0. 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.

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HORIZONTAL STABILIZER

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4.2. Vertical Stabilizer.

Most of material in the vertical stabilizer is aluminum. The rudder is graphite
composite.

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.

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VERTICAL STABILIZER
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5. WINDOWS (ATA 56).

5.1. Introduction.
These are the types of windows on the airplane :

- Flight compartment windows (fixed and sliding),

- Passenger compartment windows,
- Emergency exit windows,
- Door-mounted windows.

All the windows can hold cabin pressurization loads and have fail safe
properties.

There are ten windows in the flight compartment. There are five left (L)
windows and five right (R) windows.

Flight compartment windows No. 1, 3, 4, and 5 are fixed and do not open.
Window No. 2 is a sliding window that opens.

Interface.
Some flight compartment windows get heat from the window anti-ice system.

See the ice and rain protection chapter for more information about the
window anti-ice system. (CHAPTER 30)

WINDOWS

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FLIGHT COMPARTMENT WINDOWS

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5.2. Window n°1.

Window No. 1 has laminated glass on each side of a plastic core.
They are resistant to bird impact with or without window heat.

The inner glass pane is thicker than the outer glass pane. It is the primary
structural part. It holds the internal airplane pressure load.

The vinyl layer is a secondary structure. It is also a fail safe device that prevents
the shatter of a broken window if the inner pane breaks.

The outer pane is not structural. The outer pane gives a rigid, hard, scratch
resistant surface. A hydrophobic windshield coating is applied to the outer
pane to improve pilot visibility during rain conditions.

A conductive film on the inner face of the outer glass pane permits electrical
heating for window anti-icing and defogging. Bus bars molded into the upper
and lower edges of the windows make electrical contact with the conductive
film and connect to electrical terminals.

WARNING : BE CAREFUL WHEN YOU DO WORK ON THE WINDOW NO. 1.

THE OUTPUT VOLTAGE OF THE AUTOTRANSFORMER IS 250-350
VOLTS. THIS CAN CAUSE INJURY TO PERSONS.

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WINDOW N°1

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GLASS COCKPIT WINDOW CROSS SECTION OF EDGE SHOWING VINYL INTERLAYER CRACKING

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NOTE : The dotted line is the edge of the parting medium

All dimensions are in inches

WINDOW N°1 DELAMINATION LIMITS

WINDOW N°1 RETAINING BOLT TORQUE SEQUENCE

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5.3. Control Cabin Sliding Windows - N°2 Openable Functional Description.

Window. To open the window, operate the handle. This turns a bellcrank, which is
connected to other bellcranks at the rear, top, and bottom of the window. This
The No. 2 window is on tracks so that it may be rolled back to permit moves the window inboard. The forward roller prevents backward movement
ventilation and communication during ground handling operations. of the window until there is sufficient clearance. This lets free movement back
You can operate the right window from outside of the airplane as an to the latched open position. When the window is moved to the rear, the
emergency exit. lower aft roller moves to the window open latch plate.
The window open latch plate is spring-loaded to lock the window in the open
Physical Description. position.
The No. 2 openable window has these parts : The window is unlocked from its locked open position when you pull forward
on the latch mechanism rod. This releases the window open latch plate and
- Handle with trigger, lets the window move forward. While the window moves forward, it resets
- Bellcranks, the window open latch plate. Move the window forward by its handle until
- Push rods it touches the forward stops. As the handle is turned, the window is moved
- Clothes guard protector, outboard, guided by a guide pin in the track, until the window is closed
- Link, against the window frame. When you release the handle, a trigger bolt latches
- Springs, the window closed.
- Window open latch plate,
- Upper roller, Normal Operation.
- Upper track, To open the window, hold the trigger and turn the handle back and inboard.
- Lower roller, After the window moves inboard, move it back until it locks it in the open
- Lower track, position. To close the window, pull forward on the latch mechanism rod to
- Latch mechanism rod, unlock the window. Hold the trigger and move the window forward until you
- External access door, can turn the handle forward and outboard. When you release the trigger,
- External release handle. the window latches.

Window No. 2 has laminated glass on each side of a polyvinyl butyral (vinyl)
core. The window is resistant to bird impact with or without window heat.
The inner glass pane is thicker than the outer pane. It is the primary structure.
It holds the internal airplane pressure load. The vinyl layer is the secondary
structure. It is also a fail-safe device that prevents the shatter of the window if
the inner pane breaks. The outer pane is not structural. The outer pane gives a
rigid, hard, scratch-resistant surface.
A conductive strip on the inner face of the outer glass pane permits electrical
heating for window anti-icing and defogging.
Emergency Operation.
To open the window, push the external access door, and pull the external re-
lease handle. This will position the window inwards. Then move the window
to the rear.
Training Information Point.
WARNING : BE CAREFUL WHEN YOU DO WORK ON THE WINDOW NO. 2.
THE OUTPUT VOLTAGE OF THE AUTOTRANSFORMER IS 250-350
VOLTS. THIS CAN CAUSE INJURY TO PERSONS.

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WINDOW N°2
INSTALLATION

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5.4. Control Cabin Fixed Window - Window n° 3

Window No. 3 has two stretched acrylic panes. A phenolic spacer gives
separation between the panes. The spacer attaches to the panes by low-tack
pressure sensitive tape which also operates as an air seal. The phenolic spacer
gives an insulation cavity which prevents fog on the inner surface of the
windows.

There is a small hole in the upper forward corner of the inner pane.
This hole must be open at all times. It permits pressure in the air space to be
equal to the pressure in the cabin.

WARNING : BE CAREFUL WHEN YOU DO WORK ON THE WINDOW NO. 3.

THE OUTPUT VOLTAGE OF THE AUTOTRANSFORMER IS 250-350
VOLTS. THIS CAN CAUSE INJURY TO PERSONS.

The window has a thermal switch racket that you must align with the thermal
switch location on the glass.

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WINDOW N° 3 INSTALLATION

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5.5. Control Cabin Fixed Windows - N°4 and 5

Windows.
Windows No. 4 and 5 are almost the same. Windows No. 4 and 5 have
laminated glass on each side of a polyvinyl butyral (vinyl) core.

Window No. 4 has one more vinyl layer to prevent the shatter of broken glass
if there is a bird strike. The inner vinyl layer is not structural.

A conductive strip on the inner face of the outer glass pane permits electrical
heating for window anti-ice and window fog conditions.

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WINDOW N°4 AND N°5

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5.6. Passenger Cabin Windows Installation.

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PASSENGER CABIN WINDOWS INSTALLATION

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6. WINGS (ATA 57).

6.1. Top View.

The left wing is shown. The right wing is almost the same. Most of material in
the wing is aluminum. These components attach to the wing structure :

- Engine nacelle/pylon,
- Flight control surfaces,
- Wing tip.

Wing Reference Dimensions.

The wing has two reference dimensions. The 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.

Measure the wing station perpendicular to the wing leading edge.

You measure the wing buttock line parallel to the buttock line.

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WINGS - TOP VIEW

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6.2. Bottom View.

The bottom of the left wing is shown. The right wing is almost the same.
Fuel tank access panels allow access into the fuel tanks.

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WINGS - BOTTOM VIEW

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