Boeing ASB 737-31A1332: U.S. DOT/FAA - Service Bulletin, text

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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-31A1332 Original Issue: January 07, 2010 Revision 1: June 24, 2010 ATA System: 3100 SUBJECT: INDICATING / RECORDING SYSTEMS - Aural Warning System - Installation of the Cabin Altitude Warning System and Takeoff Configuration Warning System Lights Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery 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: January 07, 2010 737-31A1332Revision 1: June 24, 2010 1 of 229

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Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 2 of 229 BOEING SERVICE BULLETIN 737-31A1332

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Table of Contents

Revision Transmittal Sheet5

Summary9

1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3

1. Airplanes ............................................ 1 3

2. Spares Affected ........................................ 2 7 B. Concurrent Requirements ...................................... 2 7 C. Reason ................................................ 2 7 D. Description .............................................. 2 8 E. Compliance .............................................. 3 0 F. Approval ............................................... 3 0 G. Manpower .............................................. 3 1 H. Weight and Balance Changes .................................... 4 4 I. Electrical Load Data ......................................... 4 4 J. References .............................................. 4 5

1. Existing Data .......................................... 4 5

2. Data supplied with this Service Bulletin ............................ 4 5

3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 4 5 K. Publications Affected ........................................ 4 6 L. Interchangeability and Intermixability of Parts ........................... 4 6

2. MATERIAL INFORMATION ........................................ 4 7 A. Material - Price and Availability ................................... 4 7 B. Industry Support Information .................................... 4 9 C. Parts Necessary For Each Airplane ................................. 4 9

1. Kits/Parts ............................................ 4 9

2. Parts and Materials Supplied by the Operator ........................ 6 0

3. Parts Modified and Reidentified ................................ 6 1

4. Parts Removed and Not Replaced .............................. 6 3 D. Parts Necessary to Change Spares ................................. 6 3 E. Special Tooling - Price and Availability ............................... 6 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 6 3

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 5 A. GENERAL INFORMATION ..................................... 6 5 B. WORK INSTRUCTIONS ....................................... 6 6 FIGURE 1: FLIGHT COMPARTMENT - P1-3 PANEL MODIFICATION [Group 1-6, 8-12, 16-18, 20] . 95 FIGURE 2: FLIGHT COMPARTMENT - P3-1 PANEL MODIFICATION [Group 1-6, 8-12, 16-18, 20] . 97 FIGURE 3: FLIGHT COMPARTMENT - P1-3 AND P3-1 PANELS - INOP MARKERS REMOVAL AND TAKEOFF CONFIG LIGHTS REPLACEMENT [Group 7, 13-15, 19, 21] .......... 9 9 FIGURE 4: FLIGHT COMPARTMENT - P6-2 CIRCUIT BREAKER PANEL - C01698 CIRCUIT BREAKER INSTALLATION ........................................ 1 0 1 FIGURE 5: P1-3 AND P3-1 PANELS - W0001 AND W0003 WIRE BUNDLES ROUTING [Group 1-6, 8-12, 16-18, 20] ........................................... 1 0 3 FIGURE 6: CHANGES TO THE W0001 WIRE BUNDLE [Group 1-3, 5-6, 8-12, 16-18, 20] ...... 1 0 4 FIGURE 7: CHANGES TO THE W0001 WIRE BUNDLE [Group 4] ................... 1 0 6 FIGURE 8: CHANGES TO THE W0003 WIRE BUNDLE [Group 1-6, 8-12, 16-18, 20] ........ 1 0 8

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 3 of 229 BOEING SERVICE BULLETIN 737-31A1332

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FIGURE 9: W2508, W5156 AND W5514 WIRE BUNDLES ROUTING [Group 1-6] .......... 1 1 0 FIGURE 10: CHANGES TO THE W2508 WIRE BUNDLE [Group 5] ................... 1 2 0 FIGURE 11: CHANGES TO THE W2508 WIRE BUNDLE [Group 1-4, 6] ................ 1 2 2 FIGURE 12: CHANGES TO THE W5156 WIRE BUNDLE [Group 1-2, 5-6, 17-18, 20] ......... 1 2 4 FIGURE 13: CHANGES TO THE W5156 WIRE BUNDLE [Group 3] ................... 1 2 8 FIGURE 14: CHANGES TO THE W5156 WIRE BUNDLE [Group 4] ................... 1 3 2 FIGURE 15: CHANGES TO THE W5514 WIRE BUNDLE [Group 1-6] .................. 1 3 6 FIGURE 16: W0040 AND W0054 WIRE BUNDLES ROUTING [Group 1-5, 7-10, 12-21] ........ 1 3 8 FIGURE 17: CHANGES TO THE W0040 WIRE BUNDLE [Group 1-5, 7-10, 12-21] ........... 1 4 2 FIGURE 18: W0040 AND W0054 WIRE BUNDLES ROUTING [Group 6, 11] .............. 1 4 4 FIGURE 19: CHANGES TO THE W0040 WIRE BUNDLE [Group 6, 11] ................. 1 4 8 FIGURE 20: CHANGES TO THE W0054 WIRE BUNDLE ........................ 1 5 0 FIGURE 21: E1-1 ELECTRONICS SHELF - W0111 WIRE BUNDLE ROUTING ............ 1 5 2 FIGURE 22: CHANGES TO THE W0111 WIRE BUNDLE ........................ 1 5 3 FIGURE 23: W2103 WIRE BUNDLE ROUTING .............................. 1 5 5 FIGURE 24: CHANGES TO THE W2103 WIRE BUNDLE ........................ 1 6 0 FIGURE 25: CHANGES TO THE W5156 WIRE BUNDLE [Group 7] ................... 1 6 2 FIGURE 26: CHANGES TO THE W5514 WIRE BUNDLE [Group 7] ................... 1 6 5 FIGURE 27: FORWARD ELECTRONICS COMPARTMENT CEILING - CABIN ALTITUDE WARNING - CABIN HIGH ALTITUDE WARNING SWITCH (12,650 SET POINT) INSTALLATION [Group 8-9, 11, 13-14, 16-18] ......................................... 1 6 6 FIGURE 28: FORWARD ELECTRONICS COMPARTMENT CEILING - CABIN ALTITUDE WARNING - CABIN HIGH ALTITUDE WARNING SWITCH (14,000 SET POINT) INSTALLATION [Group 10, 20] ................................................. 1 6 9 FIGURE 29: P5-16 CABIN ALTITUDE AND RATE OF CLIMB MODULE - REMOVAL [Group 8-20] . . 172 FIGURE 30: P5-16 CABIN ALTITUDE AND RATE OF CLIMB MODULE - INSTALLATION [Group 8-20] . 174 FIGURE 31: P5-10 AIR CONDITIONING PANEL - REPLACEMENT [Group 8, 10-11, 13, 16-17, 20] . 176 FIGURE 32: P5-10 AIR CONDITIONING PANEL - REPLACEMENT [Group 9, 14, 18] ......... 1 7 8 FIGURE 33: W2508, W5156 AND W5514 WIRE BUNDLES ROUTING [Group 8-21] ......... 1 8 0 FIGURE 34: CHANGES TO THE W2508 WIRE BUNDLE [Group 8-11, 16] ............... 1 9 1 FIGURE 35: CHANGES TO THE W2508 WIRE BUNDLE [Group 12] .................. 1 9 5 FIGURE 36: CHANGES TO THE W2508 WIRE BUNDLE [Group 13-14] ................ 1 9 7 FIGURE 37: CHANGES TO THE W2508 WIRE BUNDLE [Group 15, 19, 21] .............. 2 0 0 FIGURE 38: CHANGES TO THE W5156 WIRE BUNDLE [Group 8-12, 16] ............... 2 0 1 FIGURE 39: CHANGES TO THE W5156 WIRE BUNDLE [Group 13-15, 21] .............. 2 0 5 FIGURE 40: CHANGES TO THE W5514 WIRE BUNDLE [Group 8-11, 16] ............... 2 0 9 FIGURE 41: CHANGES TO THE W5514 WIRE BUNDLE [Group 12] .................. 2 1 1 FIGURE 42: CHANGES TO THE W5514 WIRE BUNDLE [Group 13-14] ................ 2 1 3 FIGURE 43: CHANGES TO THE W5514 WIRE BUNDLE [Group 15, 21] ................ 2 1 5 FIGURE 44: CHANGES TO THE W2508 WIRE BUNDLE [Group 17-18, 20] .............. 2 1 6 FIGURE 45: CHANGES TO THE W5514 WIRE BUNDLE [Group 17-18, 20] .............. 2 2 0 FIGURE 46: CHANGES TO THE W5156 WIRE BUNDLE [Group 19] .................. 2 2 2 FIGURE 47: CHANGES TO THE W5514 WIRE BUNDLE [Group 19] .................. 2 2 6 APPENDIX A: P1-3 AND P3-1 PANELS - PART NUMBERS ........................ 2 2 8

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 4 of 229 BOEING SERVICE BULLETIN 737-31A1332

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Commercial Airplanes 737 Service Bulletin ALERT Revision Transmittal SheetNumber: 737-31A1332Original Issue: January 07, 2010 Revision 1: June 24, 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 revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed in accordance with the original issue of this service bulletin.

Airplanes with the high altitude landing configuration of the Cabin Altitude Warning System Groups 8-21 were added to this service bulletin effectivity.

REASON FOR REVISION This revision is sent to tell operators that airplanes with the high altitude landing configuration of the Cabin Altitude Warning System are added to this service bulletin effectivity. New Groups 8 through 21 have been created.

As a part of a service bulletin validation program, this change was completed on airplane YA010 by Service Bulletin 737-31A1332 Original Issue before the release of Revision 1 of this service bulletin. The change completed on airplane YA010 by Service Bulletin 737-31A1332 Original Issue is equivalent to the release of Revision 1 of this service bulletin. Airplane YA010 has the configuration of a Group 1 airplane.

These sections were changed:

1. In Paragraph 1.A., Effectivity and in Summary, Effectivity, deleted a note.

2. In Paragraph 1.G., Manpower, added manpower tables for new Groups 8 through 21. In Summary, Manpower, changed the table to add new Groups 8 through 21.

3. In Paragraph 1.D., Description and in Summary, Action, added a description of work for new Groups 8 through 21.

4. In Summary, changed the illustration to add work instructions for new Groups 8 through 21.

5. In Summary, Background and in Paragraph 1.C., Reason, added a validation statement and a note.

6. In Summary, Concurrent Requirements and in Paragraph 1.B., Concurrent Requirements, added a service bulletin 737-21-1171 for Group 21, Configuration 2 airplanes.

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 5 of 229

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7. In Paragraph 1.J.1., Existing Data, added Boeing Service Bulletins 737-21-1165 and 737-21-1171.

8. In Paragraph 1.J.1., Existing Data, added 737 Structural Repair Manual (SRM) Chapter 51 reference and SWPM 20-30-16 reference.

9. In Paragraph 1.J.1., Existing Data and in Paragraph 3.B., Work Instructions, added the AMM reference 737-600/700/800/900 AMM 29-11-00 for the functional test of the Auto-Land Warning Lights.

10. In Paragraph 1.K., Publications Affected, added the Airplane Flight Manual reference Section 3.

11. In Paragraph 1.K., Publications Affected, added the AMM reference 21-33.

12. In Paragraph 1.K., Publications Affected, added the Flight Crew Operations Manual references 15.20 and NNC.

13. In Paragraph 1.K., Publications Affected, added the Illustrated Parts Catalog references 21-33 and 21-51.

14. In Paragraph 2.A., Material - Price and Availability, added pricing information for top kits for new Groups 8 through 21.

15. In Paragraph 2.A., Material - Price and Availability and Paragraph 2.C.1., Kits/Parts, changed pricing information for top kits to include wire kits 280A3143-117 and 280A3143-118.

16. In Paragraph 2.B., Industry Support Information and in Summary, Industry Support Information, added new Groups 8 through 21.

17. In Paragraph 2.B., Industry Support Information and in Summary, Industry Support Information, added a note for Group 7 airplanes.

18. In Paragraph 2.C.1., Kits/Parts, added top kits for new Groups 8 through 21.

19. In Paragraph 2.C.1., Kits/Parts, added wire kits 280A3143-117 and 280A3143-118 to the top kits.

20. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, added P5-10 and P5-16 panels information and changed notes (c) and (d).

21. In Paragraph 2.C.3., Parts Modified and Reidentified and in APPENDIX A, added P1-3 and P3-1 panels part numbers.

22. In Paragraph 3.B., Work Instructions, step 1, added a note to clarify access instructions.

23. In Paragraph 3.B., Work Instructions, added a new set of instructions for the airplanes with the high altitude landing configuration of the Cabin Altitude Warning System.

24. In Paragraph 3.B., Work Instructions, Cabin Altitude Warning System, changed test instructions.

25. In Paragraph 3.B., Work Instructions, Takeoff Warning System Test, moved a warning from step (d) to step

(c).

26. In Paragraph 3.B., Work Instructions, Group 1-7, step 20, changed the 10,000ft Pressure Switch Set-point check.

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 6 of 229 BOEING SERVICE BULLETIN 737-31A1332

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27. New FIGURE 27 through FIGURE 47, added for the airplanes with the high altitude landing configuration of the Cabin Altitude Warning System.

28. FIGURE 1 through FIGURE 6, FIGURE 8, FIGURE 16 through FIGURE 24, changed the applicability to include new Groups 8 through 21.

29. FIGURE 9, changed the applicability from Group 5 to Group 1-6.

30. In FIGURE 10 and FIGURE 11, added a note.

31. In FIGURE 12, FIGURE 13 AND FIGURE 14, changed illustrations and added a wire kit 280A3143-118.

32. In FIGURE 16 and FIGURE 18, added notes.

33. In FIGURE 24, changed the illustration and added a wire kit 280A3143-117.

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

Pages with no vertical lines have no important changes.

REVISION HISTORY January 07, 2010Original Issue:

June 24, 2010Revision 1:

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 7 of 229 BOEING SERVICE BULLETIN 737-31A1332

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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-31A1332Original Issue: January 07, 2010 Revision 1: June 24, 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 Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND This service bulletin gives instructions to remove and replace the P1-3 and P3-1 instrument panels in the flight compartment with panels that include two warning level indicator lights. These indicator lights read "TAKEOFF CONFIG" and "CABIN ALTITUDE". The installation of these lights will provide a visual indication to the flight crew in addition to the existing aural warning horn for cabin altitude and takeoff configuration alerts. The visual warning lights are intended to provide an additional indication 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.

Fleet Team Digest (FTD) 737NG-FTD-31-06004 is related to this service bulletin.

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

NOTE: Operators may wish to incorporate service bulletin 737-21-1165 concurrently with this service bulletin due to common access requirements.

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 9 of 229

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ACTION (PRR 38275-118S) Group 1-6, 8-12, 16-18, 20:

Get access to the flight compartment. Remove the P1-3 and P3-1 instrument panels to install the "TAKEOFF CONFIG" and "CABIN ALTITUDE" indicator lights on the panels. Change the W0001 and W0003 wire bundles.

Install the changed P1-3 and P3-1 panels. On the P6-2 panel, install a new circuit breaker C01698. Change the W2508, W5156 and W5514 wire bundles. Change the W0040 and W0054 wire bundles. On the E1-1 electronics shelf, change the W0111 wire bundle. Change the W2103 wire bundle.

Group 8-11, 16-18, 20:

In the flight compartment, replace the existing P5-16 and P5-10 panels. At the lower forward fuselage, open the Forward Access Door 112A to get access into the area forward of the nose landing gear wheel well. On the ceiling of the forward electronics compartment, install the cabin high altitude warning switch S1172.

Group 12:

In the flight compartment, replace the existing P5-16 panel.

Group 7, 13-15, 19, 21:

Get access to the flight compartment. Remove the INOP markers from the "TAKEOFF CONFIG" and "CABIN ALTITUDE" indicator lights and replace the "TAKEOFF CONFIG" lights on the P1 and P3 panels. On the P6-2 panel, install a new circuit breaker C01698. Change the W5156 and W5514 wire bundles. Change the W0040 and W0054 wire bundles. On the E1-1 electronics shelf, change the W0111 wire bundle. Change the W2103 wire bundle.

Group 13-14:

Group 15, 19:

In the flight compartment, replace the existing P5-16 panel. Change the W2508 wire bundle.

Do a test of the "TAKEOFF CONFIG" and "CABIN ALTITUDE" indicator lights.

EFFECTIVITY 737-600/-700/-700C/-800/-900/-900ER 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 Group 1-6, 8-21:

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

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 10 of 229 BOEING SERVICE BULLETIN 737-31A1332

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Group 7:

Boeing warranty remedies are available for airplanes in warranty as of February 28, 2008. Please refer to Paragraph 2.B., Industry Support Information.

Group 7:

NOTE: The Group 7 airplanes were originally provisioned with warning lights that did not meet the Boeing design specification which require that the light lenses are not interchangeable. The Group 7 modifications in this Service Bulletin will change the configuration to meet Boeing design requirements.

MANPOWER Elapsed HoursTotal Task HoursAirplanes

36.0563.20Group 1, 3, 4

36.3063.70Group 2

36.2063.50Group 5

36.1563.30Group 6

17.8030.50Group 7

45.7580.35Groups 8, 9, 10, 11, 16

39.4569.50Group 12

27.4045.20Groups 13 and 14

21.3534.20Group 15

43.6076.05Groups 17, 18 and 20

25.1538.90Group 19

20.8533.70Group 21 The time to change the P1-3 instrument panel as given in Service Bulletins BAE Systems SB 233A2221-31-01, BAE Systems SB 233A2221-31-02 and BAE Systems SB 233A2221-31-03, and the P3-1 instrument panel as given in Service Bulletins BAE Systems SB 233A2222-31-01, BAE Systems SB 233A2222-31-02 and BAE Systems SB 233A2222-31-03 is not included.

Group 21, Configuration 2:

The time to replace the P5-16 panel as given in Boeing Service Bulletin 737-21-1171 is not included.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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

Original Issue: January 07, 2010 737-31A1332Revision 1: June 24, 2010 11 of 229 BOEING SERVICE BULLETIN 737-31A1332

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BOEING SERVICE BULLETIN 737-31A1332

ALERT ALERT GROUPS 8-20:

- REPLACE P5-16 PANEL GROUP 7, 13, 14, 15, 19:

- REMOVÉ THE INOP MARKERS GROUPS 8-11, 13-14, 16-18, 20:

FROM THE "TAKEOFF CONFIG" AND - REPLACE P5-10 PANEL "CABIN ALTITUDE" INDICATOR LIGHTS

- REPLACE THE "TAKEOFF CONFIG" LIGHTS GROUPS 1-6, 8-12, 16-18, 20: P3-1 PANEL

- CHANGE THE PANEL TO INSTALL THE "TAKEOFF CONFIG" AND "CABIN ALTITUDE" LIGHTS GROUPS 1-6, 8-12, 16-18, 20: - CHANGE WIRE BUNDLE W0001 P1-3 PANEL:

- CHANGE THE PANEL TO INSTALL THE "TAKEOFF CONFIG" AND "CABIN ALTITUDE" LIGHTS

- CHANGE WIRE BUNDLE W0003 P6-2 PANEL:

INSTALL A NEW CIRCUIT BREAKER C01698 CONDUIT:

CHANGE WIRE BUNDLES CHANGE WIRE BUNDLES WO040, W0054 W2508, W5156, W5514 AP0600B DISCONNECT P5 AFT OVERHEAD PANEL:

BRACKET: CHANGE WIRE BUNDLES

- CHANGE WIRE W2508, W5156, W5514 BUNDLE W2103.

M2061 E1-1 ELECTRONICS PROXIMITY SWITCH SHELF:

ELECTRONIC UNIT - CHANGE WIRE BUNDLE W0111 AP0900A DISCONNECT BRACKET:

- CHANGE WIRE BUNDLES W5156, W5514 AE0101B DISCONNECT

BRACKET GROUPS 8-11, 13-14, 16-18, 20:

- INSTALL THE HIGH ALTITUDE WARNING SWITCH S1172 GROUPS 8-11, 13-14, 16-18, 20:

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