Boeing ASB 737-26A1122: Revision 3, text

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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-26A1122 Original Issue:

December 13, 2007 Revision 3: January 31, 2020 ATA System: 2616 SUBJECT: FIRE PROTECTION - Lower Cargo Compartment Smoke Detection - Forward Cargo Compartment Smoke Penetration Electrical Changes Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 1 of 227

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Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 2 of 227 BOEING SERVICE BULLETIN 737-26A1122

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Table of Contents Revision Transmittal Sheet .

Summary9

1. PLANNING INFORMATION13

A. Effectivity13

1. Airplanes13

2. Spares Affected17

B. Concurrent Requirements17

C. Reason17

D. Description19

E. Compliance20

F. Approval20

G. Manpower21

H. Weight and Balance Changes27

I. Electrical Load Data27

J. References27

1. Existing Data:27

2. Data Supplied with this Service Bulletin:28

3. Installation Drawings Used in the Preparation of this Service Bulletin:28

K. Publications Affected28

L. Interchangeability and Intermixability of Parts29

M. Software Accomplishment Summary29

2. MATERIAL INFORMATION31

A. Material - Price and Availability31

B. Industry Support Information37

C. Parts Necessary for Each Airplane37

1. Kits/Parts:37

2. Parts and Materials Supplied by the Operator:52

3. Parts Modified and Reidentified:52

4. Parts Removed and Not Replaced:54

D. Parts Necessary to Change Spares54

E. Special Tooling - Price and Availability54

F. Special Tooling Necessary to do this Service Bulletin54

3. ACCOMPLISHMENT INSTRUCTIONS55

A. GENERAL INFORMATION55

B. WORK INSTRUCTIONS56

FIGURE 1: REMOVE THE J22 JUNCTION BOX ASSEMBLY89

FIGURE 2: J22 JUNCTION BOX ASSEMBLY RELAY AND WIRE BUNDLE REMOVAL92

FIGURE 3: CHANGE THE WIRE CONNECTOR HOLE SIZES ON THE J22 JUNCTION BOX ASSEMBLY

[Group 1-4; Group 5, Configuration 1; Group 6-13]96

FIGURE 4: CHANGE THE WIRE CONNECTOR HOLE SIZE ON THE J22 JUNCTION BOX ASSEMBLY

[Group 5, Configuration 2]98

FIGURE 5: W0076 WIRE BUNDLE ROUTING100

FIGURE 6: WIRE BUNDLE W0076 WIRING CHANGE101

FIGURE 7: J22 JUNCTION BOX ASSEMBLY WIRE BUNDLE AND RELAY INSTALLATION103

FIGURE 8: REMOVE THE J24 JUNCTION BOX ASSEMBLY107

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 3 of 227 BOEING SERVICE BULLETIN 737-26A1122

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FIGURE 9: J24 JUNCTION BOX ASSEMBLY RELAY AND WIRE BUNDLE REMOVAL [Group 1, 3-6, 8, 11-13] .

.110

FIGURE 10: J24 JUNCTION BOX ASSEMBLY RELAY AND WIRE BUNDLE REMOVAL [Group 2, 7, 9-10]

.114

FIGURE 11: W0080 WIRE BUNDLE ROUTING [Group 1-2, 4-13]118

FIGURE 12: W0080 WIRE BUNDLE ROUTING [Group 3]119

FIGURE 13: WIRE BUNDLE W0080 WIRING CHANGE120

FIGURE 14: J24 JUNCTION BOX ASSEMBLY MARKER INSTALLATION [Group 1, 4-6, 8, 11-13] . . 128 FIGURE 15: J24 JUNCTION BOX ASSEMBLY RELAY AND WIRE BUNDLE INSTALLATION [Group 1, 4-6,

8, 11-13]133

FIGURE 16: J24 JUNCTION BOX ASSEMBLY MARKER INSTALLATION [Group 2, 7]139

FIGURE 17: J24 JUNCTION BOX ASSEMBLY RELAY AND WIRE BUNDLE INSTALLATION [Group 2, 7]

.144

FIGURE 18: J24 JUNCTION BOX ASSEMBLY MARKER INSTALLATION [Group 3]149

FIGURE 19: J24 JUNCTION BOX ASSEMBLY RELAY AND WIRE BUNDLE INSTALLATION [Group 3] . 154

FIGURE 20: J24 JUNCTION BOX ASSEMBLY MARKER INSTALLATION [Group 9-10]159

FIGURE 21: J24 JUNCTION BOX ASSEMBLY RELAY AND WIRE BUNDLE INSTALLATION [Group 9-10]

.164

FIGURE 22: W2110 WIRE BUNDLE ROUTING169

FIGURE 23: WIRE BUNDLE W2110 WIRING CHANGE173

FIGURE 24: W2508 AND W5158 WIRE BUNDLE ROUTING [Group 1-3, 5-7, 9-13]175

FIGURE 25: WIRE BUNDLE W2508 WIRING CHANGE [Group 1-3, 5-7, 9-13]180

FIGURE 26: WIRE BUNDLE W5158 WIRING CHANGE [Group 1-3, 5-7, 9-13]182

FIGURE 27: W2508 WIRE BUNDLE ROUTING [Group 4, 8]183

FIGURE 28: WIRE BUNDLE W2508 WIRING CHANGE [Group 4, 8]185

FIGURE 29: W5100 AND W5510 WIRE BUNDLE ROUTING [Group 1-3, 5-7, 9-13]186

FIGURE 30: W5100, W5158 AND W5510 WIRE BUNDLE ROUTING [Group 4, 8]188

FIGURE 31: WIRE BUNDLE W5100 WIRING CHANGE [Group 1, 4, 6, 8]191

FIGURE 32: WIRE BUNDLE W5158 WIRING CHANGE [Group 4, 8]193

FIGURE 33: WIRE BUNDLE W5510 WIRING CHANGE [Group 1-3, 5-7, 9-13]194

FIGURE 34: WIRE BUNDLE W5510 WIRING CHANGE [Group 4, 8]196

FIGURE 35: W5110, W6210 AND W6510 WIRE BUNDLE ROUTING198

FIGURE 36: W5156 AND W6510 WIRE BUNDLE ROUTING207

FIGURE 37: WIRE BUNDLE W6510 WIRING CHANGE212

FIGURE 38: WIRE BUNDLE W5156 WIRING CHANGE214

FIGURE 39: WIRE BUNDLE W5110 WIRING CHANGE215

FIGURE 40: WIRE BUNDLE W6210 WIRING CHANGE216

FIGURE 41: INSTALL THE J22 JUNCTION BOX ASSEMBLY217

FIGURE 42: INSTALL THE J24 JUNCTION BOX ASSEMBLY220

FIGURE 43: ELECTRICAL AND ELECTRONICS COMPARTMENT - WIRE BUNDLE W5100 - WIRE CHANGE

[Group 2-3, 5, 7, 9-13]223

APPENDIX A: TESTS FOR DISTURBED SYSTEMS225

APPENDIX B: PART DEMAND INTENT227

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 4 of 227 BOEING SERVICE BULLETIN 737-26A1122

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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-26A1122Original Issue: December 13, 2007 Revision 3: January 31, 2020 ATA System: 2616 SUBJECT: FIRE PROTECTION - Lower Cargo Compartment Smoke Detection - Forward Cargo Compartment Smoke Penetration Electrical Changes This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2016-04-06 is related to this service bulletin.

Effects of this Revision on airplanes on which Original Issue, Revision 1 or Revision 2 was previously done:

None.

Airplanes YG044, YG067, YG069, YG074, YG081, YG084 and YG088 were added to new Group 13 of this service bulletin effectivity.

REASON FOR REVISION This revision is sent to add airplanes YG044, YG067, YG069, YG074, YG081, YG084 and YG088 to the effectivity of this service bulletin. Also, this revision adds new wire kits to increase the length of one wire, add optional part numbers for some connector identification tapes and filler rods, correct wire bundle W6210 routing data and correct wire bundle W5510 terminal block and splice data. A new Appendix is added to give a list of tests that can be used to function test the systems that may have been disturbed by the work done on the J22 and J24 junction boxes.

These sections were changed:

In Summary, Background, Summary Evaluation table, changed text.

2. In Summary, Compliance,

a. Added Service Related Problem (SRP).

b. Added Federal Aviation Administration (FAA) Airworthiness Directive (AD) statement.

c. Changed Boeing compliance statement and added Group 13 compliance statement.

3. In Paragraph 1.A.1., Airplanes:

a. Changed airplane applicability statement.

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b. Added airplanes and new Group 13.

In Paragraph 1.B., Concurrent Requirements, added service bulletin revision levels.

5. In Paragraph 1.C., Reason:

a. Added Service Related Problem (SRP).

b. Added revision statement.

c. Added Alternative Method of Compliance Notice (AMOC) statement.

6. In Paragraph 1.D., Description, added revision statement.

7. In Paragraph 1.E., Compliance:

a. Added FAA AD statement.

b. Changed Boeing compliance statement and added Group 13 compliance statement.

8. In Paragraph 1.F., Approval, added Alternative Method of Compliance (AMOC) statement.

9. In Paragraph 1.G., Manpower, added Group 13 data.

10. In Paragraph 1.H, Weight and Balance Changes, changed weight data.

11. In Paragraph 1.J.1., Existing Data:

a. Added service bulletin reference.

b. Added SRP reference.

c. Added FAA AD reference.

d. Added Aircraft Maintenance Manual (AMM) references.

12. In Paragraph 2.A., Material - Price and Availability:

a. Changed kit availability, pricing, ROLT data, and Group 13 data.

b. Added wire kit pricing tables.

13. In Paragraph 2.C., Parts Necessary for Each Airplane, added wire kit parts tables.

14. In Paragraph 3.A., General Information, added Appendix note.

15. In Figure 31, flag note table, changed note and added optional part numbers.

16. In Figure 34, sheet 1, changed terminal block and splice data.

17. In Figure 35, sheets 2 and 3, added wire bundle reference.

18. In Figure 40, flag note table, changed note.

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 6 of 227 BOEING SERVICE BULLETIN 737-26A1122

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19. In Figure 43, flag note table, changed note and added optional part numbers.

20.

Appendix A, added test for disturbed systems.

21. Appendix B, moved Part Demand Intent to Appendix B.

The data given in Alternative Method of Compliance Notice 737-26-1122 AMOC 01 is included in this revision.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.

Pages with no vertical lines have no changes.

REVISION HISTORY December 13, 2007Original Issue:

August 13, 2009Revision 1:

March 07, 2017Revision 2:

January 31, 2020Revision 3:

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 7 of 227 BOEING SERVICE BULLETIN 737-26A1122

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Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 8 of 227 BOEING SERVICE BULLETIN 737-26A1122

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-26A1122Original Issue: December 13, 2007 Revision 3: January 31, 2020 ATA System: 2616 SUBJECT: FIRE PROTECTION - Lower Cargo Compartment Smoke Detection - Forward Cargo Compartment Smoke Penetration Electrical Changes

THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.

CONCURRENT REQUIREMENTS Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND This service bulletin gives instructions to change the Environment Control System (ECS) to turn off the E/E Cooling Exhaust fans and open the Overboard Exhaust Valve (OEV) if a fire is detected in the forward cargo compartment. During a simulated fire test in the forward cargo compartment on 737-800 airplanes, smoke penetrated into the passenger cabin and flight deck when in the fire suppression configuration. The smoke was observed entering the passenger cabin, during steady state cruise and descent conditions, in quantities significantly higher than amounts found acceptable during previous certification tests. Small amounts of smoke were also observed in the flight deck. Accomplishment of this service bulletin will prevent smoke from entering the passenger cabin and flight deck during a cargo compartment fire.

This change will add relays and diodes to the J24 Junction Box Assembly and change the wiring. This change will also change the J22 Junction Box Assembly wiring and airplane wiring.

Boeing Service Related Problem (SRP) 737-SRP-26-0051, 737NG-SRP-26-0088 is related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane YB307 by Service Bulletin 737-26-1122 Validation Copy 1 before the release of Revision 1 of this service bulletin. The change completed on airplane YB307 by Service Bulletin 737-26-1122 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane YB307 has the configuration of Group 11 airplanes.

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 9 of 227

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ReferenceAffectedPlanning Data Paragraph 1.E., Compliance and Paragraph

1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataYesElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 38275-72S) Remove the J22 Junction Box Assembly from the airplane. Remove the relays and wire bundle W0076 from the J22 Junction Box assembly. Change the connector hole sizes and wire bundle W0076. Install the relays and changed wire bundle W0076 into the changed J22 Junction Box Assembly.

Remove the J24 Junction Box Assembly from the airplane. Remove the relays and wire bundle W0080 from the J24 Junction Box Assembly. Change wire bundle W0080 and install markers in the new J24 Junction Box Assembly.

Change wire bundles W2110, W2508, W5100, W5110, W5156, W5158, W5510, W6210 and W6510.

Install the J22 Junction Box Assembly and the J24 Junction Box Assembly.

Do a functional test of the E/E Equipment Cooling System.

EFFECTIVITY 737-600/-700/-800 Airplanes. Refer to Paragraph 1.A., Effectivity, for the list of affected airplanes.

COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2016-04-06 is related to this service bulletin.

The effective date of AD 2016-04-06 is April 1, 2016.

The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

Group 1-12:

Boeing recommends that the change given in this service bulletin be done within 51 months after the effective date of AD 2016-04-06.

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 10 of 227 BOEING SERVICE BULLETIN 737-26A1122

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Group 13:

Boeing recommends that the change given in this service bulletin be done within 51 months after the R03 issue date of SB 737-26A1122.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of October 27, 2000. Please refer to Paragraph 2.B., Industry Support Information.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

61.30101.35Group 1, 6

62.45103.60Group 2, 7

61.00102.15Group 3

61.75101.75Group 4, 8

62.00103.15Group 5 (Configuration 2)

63.15104.30Group 9-10

62.40103.55Group 5 (Configuration 1), 11, 12, 13

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

Operators are encouraged to complete the survey provided in APPENDIX B of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.

Original Issue: December 13, 2007 737-26A1122Revision 3: January 31, 2020 11 of 227 BOEING SERVICE BULLETIN 737-26A1122

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BOEING SERVICE BULLETIN 737-26A1122

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CHANGE WIRE BUNDLE W2508 CHANGE WIRE BUNDLE W6210

CHANGE WIRE BUNDLE W5156 AND W6510

CHANGE WIRE BUNDLE W5156

CHANGE WIRE BUNDLE W2110 AND W5110 CHANGE THE J24 CHANGE THE J22

JUNCTION BOX ASSEMBLY JUNCTION BOX ASSEMBLY AND WIRE BUNDLE WO080 AND WIRE BUNDLE WOO76

CHANGE WIRE BUNDLE W5100, W5158 AND W5510 1376069 Original Issue: December 13, 2007 Revision 3: January 31, 2020 Export Controlled ECCN: 9E991 - BOEING 737-26A1122 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 227

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