737 BOOK NG 00 103 - Airplane General -900ER.pdf

For training purposes onlyLEVEL 1 ATA 00 page 123 - 09 - 2013

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B737NG/00/103Airplane General -900ER

Boeing 737-900ER

Training manual

Airplane General

B737NG/00/103Airplane General -900ERTraining manual

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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 registrationscourse schedule information

Sabena technics training

[email protected]


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1.......................................23 - 09 - 20132.......................................23 - 09 - 20133.......................................23 - 09 - 20134.......................................23 - 09 - 20135.......................................23 - 09 - 20136.......................................23 - 09 - 20137.......................................23 - 09 - 20138.......................................23 - 09 - 20139.......................................23 - 09 - 201310.....................................23 - 09 - 201311.....................................23 - 09 - 201312.....................................23 - 09 - 201313.....................................23 - 09 - 201314.....................................23 - 09 - 201315.....................................23 - 09 - 201316.....................................23 - 09 - 201317.....................................23 - 09 - 201318.....................................23 - 09 - 201319.....................................23 - 09 - 201320.....................................23 - 09 - 201321.....................................23 - 09 - 201322.....................................23 - 09 - 201323.....................................23 - 09 - 201324.....................................23 - 09 - 201325.....................................23 - 09 - 201326.....................................23 - 09 - 201327.....................................23 - 09 - 201328.....................................23 - 09 - 201329.....................................23 - 09 - 201330.....................................23 - 09 - 201331.....................................23 - 09 - 201332.....................................23 - 09 - 201333.....................................23 - 09 - 201334.....................................23 - 09 - 201335.....................................23 - 09 - 201336.....................................23 - 09 - 201337.....................................23 - 09 - 201338.....................................23 - 09 - 201339.....................................23 - 09 - 201340.....................................23 - 09 - 2013

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List of EffEctivE PagEs


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tabLE of contEnts

1. RANGE.....................................................................................................6

2. DIMENSIONS...........................................................................................82.1. General..................................................................................................82.2. Fuselage Dimensions ............................................................................102.3. Wing Reference Dimensions.................................................................122.4. Vertical Stabilizer Reference Dimensions ...............................................142.5. Horizontal Stabilizer Reference Dimensions ..........................................16

3. AFT FLAT PRESSuRE BuLkhEAD .........................................................18

4. ZONE DIAGRAM ...................................................................................204.1. General................................................................................................20

5. GROuND SERVICE POINTS ...................................................................225.1. General................................................................................................22

6. ANTENNA LOCATIONS .........................................................................246.1. Antenna Location ................................................................................24

7. PRIMARY AND SECONDARY STRuCTuRES .........................................267.1. General................................................................................................26

8. COMPOSITES ........................................................................................288.1. General................................................................................................28

8. FuSELAGE .............................................................................................308.1. Internal Structure .................................................................................308.2. Cross Section ......................................................................................328.3. Forward Bulkhead & Cargo Compartment ..........................................348.4. AFT Pressure Bulkhead ........................................................................36

9. WINGS ..................................................................................................389. General ..................................................................................................389.2. Internal Structure .................................................................................409.3. Winglet ..............................................................................................429.4. Ribs & Spars .........................................................................................44

10. STABILIZERS ........................................................................................4610.1. General..............................................................................................46


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abbrEviations and acronymsList of iLLustrations

A/T Auto Throttle SystemACMS Airplane Condition Monitoring SystemACP Audio Control PanelADF Automatic Direction FinderADIRU Air Data Inertial Reference UnitAGCU APU Generator Control UnitAM AmmeterAMM Aircraft Maintenance ManualAPB APU Power BreakerAPU Auxiliary Power UnitATC Air Traffic ControlBL Buttock LineBPCU Bus Power Control UnitBTB Bus Tie BreakerCDS Comon Display SystemCDU Control Display UnitCG Center of Gravitycomm CommunicationCPS Cycle Per SecDEU Display Electronic UnitDFCS Digital Flight Control SystemDME Distance Measuring EquipmentECU Electronic Control UnitEE Electronic EquipmentEEC Electronic Engine ControlEGT Exhaust Gas TemperatureELT Emergency Locator TransmitterEMDP Electric Motor Driven PumpEPC External Power Contactorext ExternalFDAU Flight Data Acquisition UnitFLT FlightFMC Flight Management ComputerFMCS Flight Management Computer SystemFQIS Fuel Quantity Indication SystemGCB Generator Control BreakerGCU Generator Control UnitGRD GroundHF High FrequencyIDG Integrated Drive GeneratorILS Instrument Landing Systeminv InverterINOP InoperationLRRA Low range radio altimeterLRU Line replaceable unit

LSK Line Select KeysMLG Main Landing GearMIC MicrophoneNDB Non Direction BeaconNLG Nose Landing GearOFST OffesetP/B PushbuttonPDL Portable Data LoaderPDP Power Distribution Panelpwr PowerR/T Radio TransmitRTU Receiver Transmitter UnitRCCB Remote Control Ciruit BreakerSCU start converter unitSPCU Standby Power Control UnitSPKR SpeakerSPU Start Power UnitSTA Stationstby. StandbySWPM Standard Wiring Practices ManualTCAS Traffic Alert & Collision Avoidance SystemTCI Time Change ItemTRU Transformer Rectifier UnitVHF Very High FrequencyVOR VHF Omni RangeWDM Wiring Diagram ManualWL Water LineWXR Weather Radar

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


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1. rangE

General InformationThe 737 is a two-engine airplane. It is for short to medium range flights.

FeaturesThere are many new features. These new features increase the airplane payload, range and and service ceiling.


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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

GeneralDimensions 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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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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VeRtical StaBiliZeR ReFeRence DimenSionS


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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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HoRiZontal StaBiliZeR ReFeRence DimenSionS


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3. aft fLat PrEssurE buLkHEad

General DescriptionThe flat bulkhead design lets you have greater galley capability and increased seating.

LocationThe bulkhead is at station 1042.


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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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Zone DiagRam


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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 StructuresA primary structure transmits flight, ground or pressure Loads. These are the primary structures:

- Skin- Door- Landing Gear.

Secondary StructuresA 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 MaterialsThe 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.

Carbon FiberCarbon 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 ProtectionSpecial 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 contactsurfaces 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 ComponentsThe fuselage is a pressurized semi-monocoque structure made primarily of aluminum alloys.

BulkheadsPressure 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.

FramesFrames 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.

StrinqersStringers 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 BeamsFloor 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 BeamThe 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 StructuresThese auxiliary structures attach to the fuselage:

- Nose radome- Wing to body fairings- Tail cone.


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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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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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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

GeneralThe 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

GeneralThe 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. Thevertical stabilizer has a dorsal fin to help keep the airplane stable.


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StaBiliZeRS


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737 BOOK NG 00 103 - Airplane General -900ER.pdf

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