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1.

The Boeing 737 Exterior Inspection by Captain Pat BOONEPictures from Jan
PASHIDIS � Renato ZACHELLO � Krister EDLUND and Chris BRADY � author of
www.b737.org.uk Version 2.1 - Jan 20th, 2010
2. The Boeing 737 Exterior Inspection This presentation covers the Boeing 737
(Classic & Next Generation) pre-flight Exterior Inspection according the Boeing
FCOM Normal Procedures and Cold Weather Supplementary Procedures. For training
only, do not use for operation ! Always use your company publications as sole
official source ! Reference : Boeing 737 FCOM December 2009 Legend : (CL) = Classic
(NG) = Next Generation Slide 2
3. The Boeing 737 Exterior Inspection This presentation requires Microsoft�
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4. The Boeing 737 Exterior Inspection This 40 slides presentation comes with over
100 pictures and lots of extra information. Whether you are a newbie to the 737 or
an experienced Boeing 737 captain, you will certainly discover interesting items�
Don�t run through this presentation click-click-click-click-click-click � Instead,
prior to viewing the next page, challenge yourself �what am I looking for when I�m
doing the exterior inspection myself ?� and find-out that you may be overlooking
some important safety items ! Slide 4
5. The Boeing 737 Exterior Inspection This presentation is divided into 4
chapters : 1- General Guidelines 2- The Walk Around 3- Cold Weather Operations 4-
Top 10 Blunders� Slide 5
6. General guidelines
7. The Boeing 737 Exterior Inspection ? General guidelines General Guidelines -
Surfaces and structures must be clear, not damaged and not missing - Fluids should
not be leaking - Tires should not be worn, not damaged and no loose treads - Gear
struts should not be fully compressed - Engines inlet and tailpipe should be clear,
access panels should be secured, the engine exterior should not be damaged and the
reverser must be stowed
8. The Boeing 737 Exterior Inspection ? General guidelines General Guidelines -
Doors and access panels (that are not in use for servicing) should be latched -
Probes, vents and static ports must be clear and not damaged - Antennas may not be
damaged - Light lenses should be clean and not damaged
9. The Walk-aroundExterior Inspection � Normal Procedures
10. The Boeing 737 Exterior Inspection ? The Walk-Around ? Left Forward Fuselage
Left Forward Fuselage An unaspirated TAT probe (recognizable by its perforation and
a large hole at the rear of the strut) indicates a valid OAT on ground only when
probe heat is OFF and after sufficient cooling time. Exterior Inspection Probes,
sensors, ports, vents and drains ��.. Check Doors and Access Panels (not in use)
��� Latched Especially on (CL) make sure the pitot tubes and alpha vane are not
Additional Information damaged by the passenger bridge. On (NG) these probes are
moved forward. Aspirated and non-aspirated temperature probe��.. Exterior Emergency
Exit Lights���������� �Now, what are you looking for lights The exterior emergency
at this location ?� interiorsimultaneously with illuminate the emergency exit
lights. An aspirated TAT probe delivers an Exterior emergency lights are accurate
temperature measurement installed next to each entry/service (we need 2 items here)
on ground. This probe is cooled by door, overwing exits and behind APU bleed air
from the left the wing root (picture). pneumatic duct.
11. The Boeing 737 Exterior Inspection ? The Walk-Around ? Nose Nose Exterior
Inspection Radome ����������������.. Check Forward E&E Door ���������...�. Secured
The radome is made of composite material Additional Information for operation of
the WX radar. Six diverter strips transmit static build-up during normal flight.
the nose mayalso Lightning impact on These strips puncture Noise vortex Generators
������������.. decrease energydestroy the radome. to the or exceptionally and
prevent damage There After each lightning strike or bird strike, the are two E&E
access doors. This pictures ILS and WX antenna (located inside the showsradome
requires maintenance inspection. the forward E&E door. The forward door radome) in
the event of a lightning strike. provides access no the WX radar and PSEU (NG).
Even with to apparent damage on the The forward E&Efrom January 2005,E&E door be
outside, thedoor and the main may still As composite material �What are you looking
for damaged (delaminated) well) are the nose wheel on the inside ! (located aft of
Noise Vortex Generators guarded are by a single EQUIP amber (NG)on the flight deck.
installed on light to reduce the at this location ?� flight deck ambient noise
level by 3 decibel. (2 items)
12. The Boeing 737 Exterior Inspection ? The Walk-Around ? Nose Wheel Well Nose
Wheel Well Exterior Inspection Tires and wheels �.�����������.. Check Gear strut
and Doors ����������� Check Exterior Light ��������������.. Check Nose Wheel
Steering Assembly ������. Check Nose Gear Steering Lockout Pin ����. As
neededInspection Flood This is not the Gear Pin ��������������.. indicates the Dome
Light. The red line As needed light, but the maximum tow (CL)angleInspection Flood
light bar The Nose Wheel Spin Brake (snubbers) ��........ In place is a NOGO (for
tow truck drivers) aft wall) (on the Nose wheel Shimmy Dampersfor night flight !
requirement As a general rule, �3 fingers� (that is Additional Information Picture
(CL) showing both the Nose Gear Steering �What are you looking for 5 cm or 2
inches) of polished portion Lockout Pin (lower left) and the Gear Pin (top) of the
strut should be visible. inside and around Nose Wheel Well Inspection 737-800 are
sensitive to Check Some Flood Light........... tail-tipping. You may notice up to
the nose wheel well ?� (CL) Nose Wheel Down �2 hands� during off-loading. & Locked
marking....... Check Nose Wheel Steering cable assembly ���� Check (NG) Picture
Nose Wheel (7 items) Ground Crew Horn
13. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Forward Fuselage A
diverter strip above each Service/Entry Door guides away rain drops rolling down
from the fuselage. Right Forward Fuselage Exterior Inspection Probes, sensors,
ports, vents and drains ��.. Check Doors and Access Panels (not in use) ��� The
Crew Oxygen Bottle ground touched Latched avionics may not be wired These without
carrying the Oxygen Pressure Relief Green Disc ��...�.Although located in which
youservicing Theplaceglove, the E&E, find stored In APU starter hand converter unit
E&E entry door ! near the and removal are done via the forward cargoP91 reset and
compartment. Additional Information Circuit Breaker only) (CL Forward Toilet
Service Door E&E Access Door �����������..�.Closed the F/O Window Verify that E&E
Outflow Valve ���������..Check AirflowHandle ishere The Light Switch is located
flush. Escape Let�s take a look inside the E&E (NG) �What are you looking for The
Main Battery at this location ?� Don�t call maintenance for a missing screw or
bolt� ThisThe GND is the outlet for the water tiny hole SERVICE Bus drain
flexiblepoweredthe flight deck, must be tube on for the (3 items) you EQUIP Cooling
Normal on (CL) know, that annoying tube when you close theoperate� Exhaust fan to
sliding window�
14. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Wing Root, Pack
and Lower Fuselage Right Wing Root, Pack and Lower Fuselage The ATC 2 antenna
Exterior Inspection The Cargo Compartment Access Panel allows However, the light in
the forward and aft cargo you to enter the forward cargo compartment door openings
come without a lens cover. Ram Air Deflectorfrom the passenger cabin. This panel
isExtended Door �������..� located A missing or cracked lens cover must be on the
right hand side of the passenger cabin Pack and Pneumatic the 10th (737-6/700) �
���... Secured must be near Access Doors 13replaced or the light bulb th (737-
8/900) window cutout � row E, below removed,carpet. the floor as shown here. (MEL
33.04) Probes, sensors, ports, vents and drains ��.. Check Do not enter the cargo
compartment in case of Exterior Lights �������������� is Connectionthe cargo a
(spurious) smoke/fire warning. The panel Check This connection Ground Pneumatic
Before closing-up Pneumatic Manifold Duct). (into right compartment, make sure you
installed for the event that luggage is blocking Leading Edge Flapscargo door
handle. is located ondon�tright-hand side of the the �����������. Check him� the
forget about airplane because the ground engineer isTank Vent Inlet (400) Auxiliary
Fuel headset-connected on the same side. Additional Information With hydraulic
system B unpressurized, the Antenna�s ����������������Check LE Krueger flaps may
droop. Never grasp a LE Flap with your hands, Cargo Hold Lighting�������..��Check
Lens �What are you looking for because the flaps slam upwards if your fellow pilot
on the sure there is no protective cover ! Make flight deck pressurizes system B
(NG) Cargo Hold Access Panel���������� along this side ?� on the static ports. (CL)
Auxiliary Fuel Tank Vent����������.. inletarefree of FOD, Protective covers are
installed for the Make also sure These 4 flat antenna�s is several reasons,
including maintenance, Landing Light including clothing stowed away by (NG)
Retractable (5 items) painting, washing or ground personnel Air 1 and summer day.
(into the Ground the Radiothe inleton a hot 2 to protect Altimeter Connection
(Pack) Pre-conditioned Antenna VHF against insects duringTransmitter of the
Groundconnection is located a stopover.and Receiver Pneumatic Main Distribution
Manifold). The COMM 2 Connection Detail (CL) on the left-hand sideon the (NG) COMM
3 the airport�s (Pack) of the left-hand since airplane, side air-conditioning
system is integrated into the jetway.
15. The Boeing 737 Exterior Inspection ? The Walk-Around ? Airconditioning Bay
Airconditioning Bay Ram Air Inlets While we are here, let�s take a brief look
inside the airconditioning bay. The airconditioning bays are located on each side
of the wing roots, forward of the main wheel well. The air-cycle machine The Water
Separator The right pack heat exchangers. Air conditioning Outlet Outlets
16. The Boeing 737 Exterior Inspection ? The Walk-Around ? Number 2 Engine Number 2
Engine Exterior Inspection Access Panels �������������notice an engine oil leakage
If you Latched during the pre-flight exterior Probes, sensors, ports, vents and
drains inspection, call maintenance. ��.. Check Fan Blades, Probes and Spinner
������ Check number of The maximum allowed drops per minute differs by engine
Thrust Reverser ������������... Stowedsection. type and by engine Exhaust area and
Tailcone ��������.. Check Additional Information Alignment of these black indicator
Generator Drive Oil system������������ strips indicate proper stowage of to call
You don�t need the left and right thrust reverser missing bolts. maintenance for
Oil leakage����������....Checkfocusholes are used to rear �What are you looking for
sleeve. If view within limit These on this frame A you into the engine from the
with detach the the engine (open). seconds, nosefor hot cone. for 5the reverser
deployed surfaces Caution at this location ?� fan starts toafter recent flight
rotate� A small puddle T12 Total Inlet Temperature Sensor of oil in the engine
exhaustThe oil level indication has a different of a red locking plug is
acceptable. will notice the top (5 items) You A large puddle may cause heavy
ifengine scale for the left pin here smoke and right the reverser is dispatched and
exceptionallyof the wing fire up to because a tail pipe dihedral inoperative
(locked). 10 minutes after engine shutdown.
17. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Wing and Leading
Edge Right Wing and Leading Edge Picture of cold soaked fuel frost on lower wing
surface. This picture is taken after descent Exterior Inspection in VMC and landing
at an airfield with ambient Don�t call maintenance to temperature above 35 �C / 95
�F !! Access Panels ������������� notice there is no ice on the flaps ! fuel Also
Latched Defined cold-soaked report holes in the leading edge ! These holes serve
Leading Edges Flaps and Slats ������. Check frost area painting (NG) as wing anti-
icing air outlet ! Fuel Measuring Sticks �����.. Flush and secure Wing Surfaces
�������������.. Check Fuel Tank Vent �������������. Check (NG) Do you recall the
Cold soaked Fuel Frost Limits ? Additional Information The defueling bay door
cannot be Lower Wing : Max. 3 mm or 1/8 inch if the defueling valve is open. closed
This valve is Wing anti-icing Wing Anti-Ice Exhaust �������������.duct manually
operated Only on the wing itself, not(shown here). on the by a handle air supply
flight controls, LE/TE Flaps/Slats �What are you looking forwinglets. and not on
along the leading edge Upper Wing : Max. 1,5 mm or 1/16 inch Pressure of the right
wing ?� > 0�C or Poppet is flush with the wing OAT Check that Flame Arrestor Valve
32�F lower skin. No visible moisture If the valve is popped wing inwards, it (5
items) Only within thereset by maintenance. must be painted area LE slats actuator
Similar on both wings (!)
18. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Wing Tip and
Trailing Edge Right Wing Tip and Trailing Edge Exterior Inspection Picture (NG) :
The deflection of the flight spoilers deploy is less than Position and Strobe
Lights ��������... Check the ground spoilers. On NG with the SFP (Short Field
Static Discharge Wicks ����������. Check installed, the Performance) option Aileron
and TE Flaps �����������.angle is further increased. deflection Check Additional
Information Any idea about the number of static Flight and Ground Spoilers
������������ dischargers installed on each wing ? Main Wing : 4 MEL 33-11 is rather
complicated due to �WhatWing (with looking different plastic lenses (single or
dual) Main are you blended winglets) : 2 for at this location ?� and winglets
installed or not. As a general rule at least one red and Horizontal Stabilizer : 3
one green navigation light must operate for night flight. (3 items) This picture
shows a 737-800 with a dual Vertical Stabilizer : 4 plastic lens and blended
winglets.
19. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Main Gear Right
Main Gear Exterior Inspection Tires, Brakes and Wheels ��������... Check Gear
Strut, Actuators and Doors ������ Check Gear Pin ������������..�� As needed
Hydraulic Lines �������������. Secure tire wear limits Refer to your company
manuals and procedures for or call maintenance. Additional Information As a general
rule, the strut should be extended by �3 fingers� with passengers Brake
Temperature���������������. and fuel loaded. brake wear indicator pin If one is
missing, the brake can stay in service if operation of the The aircraft can be pin
is satisfactory. remaining dispatched with Parking brakes must set in order to
check �What are you looking for one, two If aall three main landing or pin is
broken, just consider the brake wear indicator pins. gear doorsmissing� Refer to
the it � option) (NG missing. both brake pins flush, the With one or at the right
main landing gear ?� DDG-CDL forTemppenalties and MFD Brake fuel display on the
rejected takeoff. brakes can still handle one maintenance actions. According to the
Maintenance Manual AMM 32-41 you may not leave with a flush pin. (4 items) Check
your company SOP.
20. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Main Wheel Well
Right Main Wheel Well When the hydraulic fluid return filter is Exterior Inspection
Thisclogged, a like a hydraulic pressure may look red differential fluid
leak�indicator will appear on top of the filter APU Fire Control Handle
�������...���.�F).the uses over- (if OAT isMLG uplock mechanism The above 2 �C � 36
Up However, what locking toindicator, call fitting is broken, (NG) If The flightyou
notice thesee here is the main landing center you red with an If can be dispatched
keepboth (NG � as installed) NGS light �����...��theTwo be raised after takeoff.
Check main wheel gear (dome) lights inoperative landing gear anti-corrosiveup and
locked. associated hold the well protection compound maintenance� springs cannot
locked position. Anyway, uplock hook in doubt, and if there is any the up Wheel
Well ���������������.. Check disappeared (CL) an inoperative inspection call
maintenance. It has happened that a spring However, on The FCOM does not specify
what to check, (if you found it in your garden, is a NOGO for night flight ! in
flight please return to company) flood light (two installed � one for each gear) so
here are some suggestions : - General condition (no loose cables, no fluid leaks) -
Hydraulic System Quantity, Pressure and Filters - Landing Gear Up-Lock system �What
are you looking for System both the Fire Handle and the - (CL) Landing Gear Viewing
Verify that Bottle Discharge Switch are safety wired. in (NG)Right Main Wheel
Well ?� - the Loose Thread Frangible Fitting Verify that the operability green
indicator light is illuminated, unless the NGS is (6 items) dispatched inoperative.
21. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Main Wheel Well
Inside the Main Wheel Well There is a relatively large empty space Additional
Information next to and aft of each flap transmission. The F/O Flight Control
Spoiler quadrant, It can even hide aspoiler Mixer, mounted The stowaway. Always
worth a double check� through cables connected with the F/O should be The handle on
the forward side on the forward wall. A short guided tour inside flight deck
control wheel wired and pointing upwards. The handle is the Main Wheel Well : for
maintenance only. If the handle is rotated, the engine reverser is de-activated�
(NG) This is the center tank boost pump. The CAPT Flight Control aileron
quadrant,You can find six of these through cables connected with the Captain�s
mounted in the forward flight deck control The TE Flaps hydraulic systemand the
wheel This is the motor A EMDP wall. (Electric Motor Driven Pump). alternate
electric motor are integrated in the same housing on the aft wall of the wheel
well. Both motors drive the TE flaps through common orange/black Mounted on the
forward part of the system B EMDP B painted shafts. is This Hydraulic system the
keel beam, this is the (Electric Motor Driven Pump). PTU. reservoir pneumatic The
systemair EDP (Engine B pressure indicator Driven Pump) is located in� The
accumulator brake Engine 2 of course. This this indicator pressure Thrust Reverser
Control Valve (NG) TE Flap Transmission : hydraulic system reservoir The Standby is
theunit transmits power from the orange/black keel beam. for Engine 2. is located
on the center torque shaft to the TE flaps for(NG).side. This picture is that So,
there are two of these beasts Hydraulic system B installed in the wheel well.
Pressure Module
22. The Boeing 737 Exterior Inspection ? The Walk-Around ? Right Aft Fuselage Right
Aft Fuselage Exterior Inspection Doors and Access Panels �����.��� Latched Negative
Pressure Relief Door ���..��� Closed Compartment (NG) Aft Cargo Outflow Valve
�����������.��� Check Behind this bulkhead is the toilet Antenna VHF waste tank and
the compressor. Probes, sensors, ports, vents and drains ��.. Check (CL) COMM 3 APU
Air Inlet ��������������� Open (NG) COMM 2 (CL) APU Fire Bottle �������...�..��
Check (CL) Verify that the Squib Discharge disc (yellow) Additional Information
looking �What are you for and the Bottle Overpressure disc (red) are in place along
the aft fuselage ?� recent delivered (NG) the main service panel is located on On
The water Toilet Waste System�������������..right side (NG) � left side (CL) of
outflow valve comes with �teeth� to the Verify the cargo compartment entry picture
is (NG). (6 Comm NG) (7 items reduce aerodynamic noise. the airplane. This VHF
items -Antenna�������������..toilet service panel is located on CL) for any dents�
The the opposite side, with an extra toilet access panel in the front (CL).
23. The Boeing 737 Exterior Inspection ? The Walk-Around ? Tail Tail APU Cooling
Air Inlet Exterior Inspection Vertical Stabilizer and Rudder �����..�.. Check
Horizontal Stabilizer and Elevator �����.. Check Elevator Feel Probes �����������
Check (400-800-900) Tail Skid ..���������. Check Static Discharge Wicks
���������.... Check Strobe Light ��������������� Check APU Cooling Air Inlet and
Exhaust Outlet �.� Check �What are you looking for around the tail ?� (8 items) APU
Exhaust Outlet
24. The Boeing 737 Exterior Inspection ? The Walk-Around ? Tail Tail Location of
the VOR/LOC antenna Additional Information The famous Stab Logo
Light������������������� trim jackscrew Horizontal Stabilizer-to-Body Sliding
Seals����� Antenna HF and VOR�������������� The APU inletsteering cables, The
rudder door as seen from the Now, let�s take a look, where you have inside. This
here isflight deck door connected to the the electric actuator. pedals. never been
before, inside the tail cone : rudder Stabilizer Trim system ������������.. APU
Inlet Door system ������������. Location of the HF antenna APU Fire Extinguisher
system ���������. or lower seal is If the upper The electric Stab trim actuator
maintenance. missing, call Other �������������������� When dispatched with the seal
removed, apply the performance weight penalties (NG) The logo light is powered from
from the DDG / CDL. The Stab trim Main Bus 1. Hence the logo lights control cable
drum. The cables are connected to the The aft pressure bulkhead isilluminate with
the CAB/UTIL do not flight on 737-100 thruin OFF�! hemispheric switch 800 deck
manual trim wheels. and flat on the 900
25. The Boeing 737 Exterior Inspection ? The Walk-Around ? Left side Left side
Differences with Right Side As a general rule both pressure indicators should point
upwards. Left Aft Fuselage : When you return to the flight deck, may tend slightly
to the left They on cold days and slightly to the right (NG) Waste Compressor Vent
����. Check Very often,days as pressure inside the take a look at these drains. on
hot the drains are clogged ! bottles changes with OAT. These drains guide away rain
water that has entered the cabin through the Left Main Wheel Well : associated
door. A clogged drain may Fire Discharge Bottles ������...�. Check into the E&E,
cause rain water to seep causing damage to electronics. During the exterior
inspection Additional Information you may notice the sound of the vacuum compressor
Entry / Service Door Floor Drains ����. toilets.cabin crew flushes when the the
Check �What additional items will you be checking A malfunctioning air/waste
separator may direct waste on the left side of the airplane ?� to the air outlet
i.s.o. towards the waste tank� (2 items - NG) (1 item � CL) So here is a good
advice : stay away from this hole !
26. Cold Weather OperationsExterior Inspection � Supplementary Procedures
27. The Boeing 737 Exterior Inspection ? Cold Weather Operations Pay extra
attention to the following items : Surfaces ��������������������������� Check
Control Balance Cavities �������������������� Check Pitot Probes and Static ports
������������������. Check Air Conditioning Inlets and Exits ����������������� Check
Engine Inlets �������������������������. Check Fuel Tank Vents
�����������������������... Check Landing Gear Doors ���������������������.... Check
APU Air Inlets ������������������������... Check
28. The Boeing 737 Exterior Inspection ? Cold Weather Operations Some Pictures :
Clear ice on the leading edge Ice formation on the engine fan after a short taxi
time Ice formation in the engine inlet Ice formation on the pitot tubes
29. Top 10 Blunders !In fact, we can as well start withthis classic one :Tools or
an oil can accidentallyleft behind in the main wheel wellby maintenance personnel.
30. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 10 How about these
3 tools�? General condition OK ?
31. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 9 A large dent in
the fuselage may easily go unnoticed�
32. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 8 Don�t tell me I
didn�t warn you !
33. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 7 OK, what�s wrong
here ? (NG) The main gear frangible fitting may never be used to attach the fuel
truck ground wiring cable !
34. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 6 There is no
potential danger that the door opens in flight when the Z-Handle is not correctly
stowed. However, you will probably experience additional ambient noise in flight�
35. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 5 OK, what�s wrong
here ? This rod is broken, so you will be flying with the right nose wheel well
door open�
36. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 4 During the walk-
around in heavy rain, you may perhaps not be looking upwards� and these missing
access panels from the Horizontal Stabilizer may go unnoticed� Furthermore, always
pay extra attention to access panels when the airplane is being returned from
maintenance.
37. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 3 Anything wrong
here ? (CL) While the gear pin may have drawn your attention, you should also have
noticed that the red painting is missing and/or covered with lubricating oil� This
is a NOGO !
38. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 2 This engine looks
in good shape ? You caught a bird into the N2 compressor during landing. This may
go unnoticed, especially during a night time walk-around without carrying a flash-
light�
39. The Boeing 737 Exterior Inspection ? Top 10 Blunders Number 1 The (smaller)
main wheel of a Boeing 737-500 And our Number 1 winner mounted on the Boeing 737-
400� today is� ??? So, always take a look to the wheels !
40. The Boeing 737 Exterior Inspection the end - for more information
www.B737MRG.net www.B737.org.uk Have a safe flight ! Slide 40

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