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Boeing ASB 737-31A1325: U.S. DOT/FAA - Service Bulletin

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© The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2010-0761; AD 2011-03-14 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.

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January 11, 2010 737-31A1325 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 214

ALERT ALERT Commercial Airplane Group 737

ALERTALERT Service Bulletin Number: 737-31A1325 Date: January 11, 2010 ATA System: 3100 SUBJECT: INDICATING / RECORDING SYSTEMS - Aural Warning System - Installation of the Cabin Altitude Warning System and Takeoff Configuration Warning System Lights

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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Table of Contents January 11, 2010 737-31A1325 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 214 BOEING SERVICE BULLETIN 737-31A1325

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Table of Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 61

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 61 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 62

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 68

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 73

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 FIGURE 1: P2-2 CENTER INSTRUMENT PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . 83 FIGURE 2: MODIFICATION OF THE P2-2 CENTER INSTRUMENT PANEL. . . . . . . . . . . . . . 85 FIGURE 3: LIGHT ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 FIGURE 4: WIRE BUNDLE W066 WIRE ROUTING - GROUPS 1-29, 31-36, 38 AND 43 AIRPLANES 91 FIGURE 5: WIRE BUNDLE W066 WIRE ROUTING - GROUP 37 AIRPLANES . . . . . . . . . . . . 92 FIGURE 6: WIRE BUNDLE W066 WIRE ROUTING - GROUPS 30, 39-42 AND 44-48 AIRPLANES . 93 FIGURE 7: WIRE BUNDLES W002 AND W066 WIRE ROUTING - GROUP 49 AIRPLANES . . . . . 94 FIGURE 8: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 14 AND 17 AIRPLANES . . . . . . 96 FIGURE 9: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 1, 4, 24 AND 43 AIRPLANES . . . 98 FIGURE 10: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 15 AND 25 AIRPLANES . . . . . 100 FIGURE 11: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 6 AND 23 AIRPLANES . . . . . . 102 FIGURE 12: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 7 AND 8 AIRPLANES . . . . . . . 104

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FIGURE 13: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 5 AND 9 AIRPLANES . . . . . . 106 FIGURE 14: WIRE BUNDLE W066 WIRING CHANGE - GROUP 10 AIRPLANES . . . . . . . . . . 108 FIGURE 15: WIRE BUNDLE W066 WIRING CHANGE - GROUP 16 AIRPLANES . . . . . . . . . . 110 FIGURE 16: WIRE BUNDLE W066 WIRING CHANGE - GROUP 3 AIRPLANES . . . . . . . . . . . 112 FIGURE 17: WIRE BUNDLE W066 WIRING CHANGE - GROUP 18 AIRPLANES . . . . . . . . . . 114 FIGURE 18: WIRE BUNDLE W066 WIRING CHANGE - GROUP 19 AIRPLANES . . . . . . . . . . 116 FIGURE 19: WIRE BUNDLE W066 WIRING CHANGE - GROUP 20 AIRPLANES . . . . . . . . . . 118 FIGURE 20: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 21 AND 22 AIRPLANES . . . . . 120 FIGURE 21: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 2 AND 13 AIRPLANES . . . . . 122 FIGURE 22: WIRE BUNDLE W066 WIRING CHANGE - GROUP 11 AIRPLANES . . . . . . . . . . 124 FIGURE 23: WIRE BUNDLE W066 WIRING CHANGE - GROUP 26 AIRPLANES . . . . . . . . . . 126 FIGURE 24: WIRE BUNDLE W066 WIRING CHANGE - GROUP 27 AIRPLANES . . . . . . . . . . 128 FIGURE 25: WIRE BUNDLE W066 WIRING CHANGE - GROUP 28 AIRPLANES . . . . . . . . . . 130 FIGURE 26: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 12 AND 29 AIRPLANES . . . . . 132 FIGURE 27: WIRE BUNDLE W066 WIRING CHANGE - GROUPS 31 AND 32 AIRPLANES . . . . . 134 FIGURE 28: WIRE BUNDLE W066 WIRING CHANGE - GROUP 33 AIRPLANES . . . . . . . . . . 136 FIGURE 29: WIRE BUNDLE W066 WIRING CHANGE - GROUP 34 AIRPLANES . . . . . . . . . . 138 FIGURE 30: WIRE BUNDLE W066 WIRING CHANGE - GROUP 35 AIRPLANES . . . . . . . . . . 140 FIGURE 31: WIRE BUNDLE W066 WIRING CHANGE - GROUP 36 AIRPLANES . . . . . . . . . . 142 FIGURE 32: WIRE BUNDLE W066 WIRING CHANGE - GROUP 37 AIRPLANES . . . . . . . . . . 144 FIGURE 33: WIRE BUNDLE W066 WIRING CHANGE - GROUP 38 AIRPLANES . . . . . . . . . . 146 FIGURE 34: WIRE BUNDLE W066 WIRING CHANGE - GROUP 39 AIRPLANES . . . . . . . . . . 148 FIGURE 35: WIRE BUNDLE W066 WIRING CHANGE - GROUP 40 AIRPLANES . . . . . . . . . . 150 FIGURE 36: WIRE BUNDLE W066 WIRING CHANGE - GROUP 41 AIRPLANES . . . . . . . . . . 152 FIGURE 37: WIRE BUNDLE W066 WIRING CHANGE - GROUP 42 AIRPLANES . . . . . . . . . . 154 FIGURE 38: WIRE BUNDLE W066 WIRING CHANGE - GROUP 30 AIRPLANES . . . . . . . . . . 156 FIGURE 39: WIRE BUNDLE W066 WIRING CHANGE - GROUP 44 AIRPLANES . . . . . . . . . . 158 FIGURE 40: WIRE BUNDLE W066 WIRING CHANGE - GROUP 45 AIRPLANES . . . . . . . . . . 160 FIGURE 41: WIRE BUNDLE W066 WIRING CHANGE - GROUP 46 AIRPLANES . . . . . . . . . . 162 FIGURE 42: WIRE BUNDLE W066 WIRING CHANGE - GROUP 47 AIRPLANES . . . . . . . . . . 164 FIGURE 43: WIRE BUNDLE W066 WIRING CHANGE - GROUP 48 AIRPLANES . . . . . . . . . . 166 FIGURE 44: WIRE BUNDLE W066 WIRING CHANGE - GROUP 49 AIRPLANES . . . . . . . . . . 168 FIGURE 45: WIRE BUNDLE W002 WIRE ROUTING - GROUPS 1-29, 31, 38 AND 43 AIRPLANES. 170 FIGURE 46: WIRE BUNDLE W002 WIRE ROUTING - GROUPS 30, 39-42 AND 44-48 AIRPLANES 171 FIGURE 47: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 1, 3, 5-10, 15-20, 23 AND 25 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 FIGURE 48: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 2, 13 AND 21-22 AIRPLANES. . 174 FIGURE 49: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 11 AND 26-28 AIRPLANES . . . 176 FIGURE 50: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 12, 29, 31 AND 32 AIRPLANES . 178 FIGURE 51: WIRE BUNDLE W002 WIRING CHANGE - GROUP 33 AIRPLANES . . . . . . . . . . 180 FIGURE 52: WIRE BUNDLE W002 WIRING CHANGE - GROUP 34 AIRPLANES . . . . . . . . . . 182 FIGURE 53: WIRE BUNDLE W002 WIRING CHANGE - GROUP 35 AIRPLANES . . . . . . . . . . 184 FIGURE 54: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 36 AND 37 AIRPLANES . . . . . 186 FIGURE 55: WIRE BUNDLE W002 WIRING CHANGE - GROUP 38 AIRPLANES . . . . . . . . . . 188 FIGURE 56: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 4, 14 AND 43 AIRPLANES . . . 190 FIGURE 57: WIRE BUNDLE W002 WIRING CHANGE - GROUP 24 AIRPLANES . . . . . . . . . . 192

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FIGURE 58: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 30 AND 39-42 AIRPLANES. . . . 194 FIGURE 59: WIRE BUNDLE W002 WIRING CHANGE - GROUPS 44, 45, 46, 47 AND 48 AIRPLANES .

196 FIGURE 60: WIRE BUNDLE W002 WIRING CHANGE - GROUP 49 AIRPLANES . . . . . . . . . . . 198 FIGURE 61: WIRE BUNDLE W246 WIRE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . 200 FIGURE 62: WIRE BUNDLE W246 WIRING CHANGE - GROUPS 1, 3, 5, 8, 10, 11, 13, 15-21, 23, 26-31, 33-34, 36-39, 41-42, 44 AND 46-49 AIRPLANES . . . . . . . . . . . . . . . . . . . . 203 FIGURE 63: WIRE BUNDLE W246 WIRING CHANGE - GROUPS 2, 6, 7, 9, 12, 22, 25, 32, 35, 40 AND 45 AIRPLANES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 FIGURE 64: WIRE BUNDLE W246 WIRING CHANGE - GROUPS 4 AND 14 AIRPLANES . . . . . . 207 FIGURE 65: WIRE BUNDLE W246 WIRING CHANGE - GROUP 24 AIRPLANES . . . . . . . . . . . 209 FIGURE 66: WIRE BUNDLE W246 WIRING CHANGE - GROUP 43 AIRPLANES . . . . . . . . . . . 211 FIGURE 67: P2-2 CENTER INSTRUMENT PANEL INSTALLATION . . . . . . . . . . . . . . . . . . 213

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Original Issue: January 11, 2010 737-31A1325 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 214

ALERT ALERT Commercial Airplanes 737

ALERTALERT Service Bulletin Number: 737-31A1325 Summary Original Issue: January 11, 2010 ATA System: 3100 SUBJECT: INDICATING / RECORDING SYSTEMS - Aural Warning System - Installation of the Cabin Altitude Warning System and Takeoff Configuration Warning System Lights

THIS BULLETIN 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 SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

CONCURRENT REQUIREMENTS None

BACKGROUND This service bulletin gives instructions to install two warning level indicator lights on the P2-2 center instrument panel in the flight compartment. The installation of these lights will provide a visual indication to the flight crew to be used in conjuction with the existing aural warning horn for cabin altitude and takeoff configuration alerts.

The visual warning lights are intended to provide additional notice to crews to prepare a correct takeoff configuration, respond to excessive cabin altitude and avoid confusion between the takeoff configuration and cabin altitude alerts. An unrecognized incorrect takeoff configuration or excessive cabin altitude could prevent a continued safe flight and landing.

As a part of a service bulletin validation program, this change was completed on airplane PW234 by Service Bulletin 737-31A1325 Validation Copy 1 and Installation Deviation Records 737-31A1325-001 through 737- 31A1325-006 before the initial release of this service bulletin. The change completed on airplane PW234 by Service Bulletin 737-31A1325 Validation Copy 1 and Installation Deviation Records 737-31A1325-001 through 737-31A1325-006 is equivalent to the initial release of this service bulletin. Airplane PW234 has the configuration of a Group 13 airplane.

Boeing Service Related Problem (SRP) 737-SRP-31-0042 is related to this service bulletin.

ACTION Get access to the flight compartment. Remove the P2-2 center instrument panel to install two warning level indicator lights on the panel and change three wire bundles. Reinstall the modified P2-2 center instrument panel. Do a test of the warning level indicator lights.

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EFFECTIVITY All 737-100/-200/-200C/-300/-400/-500 Airplanes. Refer to Paragraph 1.A.1 Airplanes, for the list of affected airplanes.

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

Boeing recommends that the change given in this service bulletin be done within 36 months after the date on this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Airplanes Total Task Hours Elapsed Hours Groups 1-49 32.50 20.50

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MODIFY P2-2 PANEL AND

INSTALL LIGHT ASSEMBLIES P2-2 CENTER

INSTRUMENT PANELCHANGE WIRE

BUNDLES W002 AND W066 P6 LOAD CONTROL CENTER

CHANGE WIRE BUNDLE W246 P9 PANEL 1376079

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Original Issue: January 11, 2010 737-31A1325 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 214

ALERT ALERT Commercial Airplanes 737

ALERTALERT Service Bulletin Number: 737-31A1325 Original Issue: January 11, 2010 ATA System: 3100 SUBJECT: INDICATING / RECORDING SYSTEMS - Aural Warning System - Installation of the Cabin Altitude Warning System and Takeoff Configuration Warning System Lights

THIS BULLETIN 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 SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below. Refer to PRR 35005-277RS for data about this change.

GROUP CONFIGURATION DESCRIPTION 1 - Wiring and P2 panel configuration differences 2 - Wiring and P2 panel configuration differences 3 - Wiring and P2 panel configuration differences 4 - Wiring and P2 panel configuration differences 5 - Wiring and P2 panel configuration differences 6 - Wiring and P2 panel configuration differences 7 - Wiring and P2 panel configuration differences 8 - Wiring and P2 panel configuration differences 9 - Wiring and P2 panel configuration differences 10 - Wiring and P2 panel configuration differences 11 - Wiring and P2 panel configuration differences 12 - Wiring and P2 panel configuration differences 13 - Wiring and P2 panel configuration differences

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Airplane models:

14 - Wiring and P2 panel configuration differences 15 - Wiring and P2 panel configuration differences 16 - Wiring and P2 panel configuration differences 17 - Wiring and P2 panel configuration differences 18 - Wiring and P2 panel configuration differences 19 - Wiring and P2 panel configuration differences 20 - Wiring and P2 panel configuration differences 21 - Wiring and P2 panel configuration differences 22 - Wiring and P2 panel configuration differences 23 - Wiring and P2 panel configuration differences 24 - Wiring and P2 panel configuration differences 25 - Wiring and P2 panel configuration differences 26 - Wiring and P2 panel configuration differences 27 - Wiring and P2 panel configuration differences 28 - Wiring and P2 panel configuration differences 29 - Wiring and P2 panel configuration differences 30 - Wiring and P2 panel configuration differences 31 - Wiring and P2 panel configuration differences 32 - Wiring and P2 panel configuration differences 33 - Wiring and P2 panel configuration differences 34 - Wiring and P2 panel configuration differences 35 - Wiring and P2 panel configuration differences 36 - Wiring and P2 panel configuration differences 37 - Wiring and P2 panel configuration differences 38 - Wiring and P2 panel configuration differences 39 - Wiring and P2 panel configuration differences 40 - Wiring and P2 panel configuration differences 41 - Wiring and P2 panel configuration differences 42 - Wiring and P2 panel configuration differences 43 - Wiring and P2 panel configuration differences 44 - Wiring and P2 panel configuration differences 45 - Wiring and P2 panel configuration differences 46 - Wiring and P2 panel configuration differences 47 - Wiring and P2 panel configuration differences 48 - Wiring and P2 panel configuration differences 49 - Wiring and P2 panel configuration differences

GROUP CONFIGURATION DESCRIPTION

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