Aviation Partners Boeing Service Bulletin AP737-27-002

I. WEIGHT AN D BA LA NCE CHANGES ................................................................... .. ................ 11 J. ELE CTRICAL LOAD DATA ............... .. ...... .. ........................................................ .... ............... 11 K. REF ERENC ES................... .. ................. .. .............................................................................. 11 L. PUBLICATI ONS AFFECTED ................................................................................................. 13 M. I NTERCHANGEAB ILI TY AN D INTERMIXABI LITY OF PARTS ................................................. 14 N. SOFTWARE ACC OMPLISHMENT SUMMA RY ..................................................................... 14 2. M ATERIAL INFO RMATION .. ............................ ....... .... .. ............................................... 15 A. MATERIAL- PRICE AN D AVAILABILITY ............................................................................... 15 B. PARTS NECESSARY TO CHANGE EACH AIR PLA NE ............................ .. ... .. ........................... 15 c. SPECIAL TOOLING - PR I CE AND AVAILABILITY .......................... .. ................. .. .................... 17 D. SPECIAL TOOLING NECESSARY TO DO T HIS SERVICE BU LLET IN ................................... ...... 18 3. ACCOMPLISHMENT INSTRUCTIONS ....•.....•............................... •........... .. •.........•..•...... 19 A. GENERAL NOTES ................................................................................................................ 19 B. WORK INSTRUCTIONS ....... .. .............................................................................................. 21 Original Issue: March 31 , 2015 Revision 4: April24, 2017 AP737 -27-002 Page 2 of 54 Aviation Partners Boeing PROPRIETARY AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 List of Tables Title Page Table 1 - Manpower .......... .. .. .. ........................................................................... .. ......... 10 Table 2- Parts Available from APB ............................................................................... 15 Table 3 - Parts and Material Supplied by the Aircraft Owner/Operator .. ........ . .. .......... .. 15 Table 4 - Special Tooling Necessary to Do Th is Service Bulletin ................ .............. . ... 18 Table 5 - FMC Software Part Number and Compatibility .... . ... . .. .. .. ............................... . 47 Li st of Fi gures Title Page Figure 1: Areas of Work 8 Figure 2: PART 1 Work Flow 24 Figure 3: Access to Stabilizer Takeoff Warning Sw itch 25 Figure 4: Stabilizer Takeoff Warning Switch 26 Figure 5: Single Takeoff Warning Switch Re location with an Ex isti ng Hole 27 Figure 6: Single Takeoff Warning Switch Relocation with an Existing Hole- Detail 28 Figure 7: Single Takeoff Warning Switch Relocation with New Holes 29 Figure 8: Single Takeoff Warning Switch Relocation with New Holes- Detail 30 Figure 9: PART 2 Work Flow 34 Figure 10 : Double Takeoff Warning Switch Relocation with Existing Holes 35 Figure 11 : Double Takeoff Warning Switch Relocation with Existing Holes - Detail 36 Figure 12 : Double Takeoff Warning Switch Relocation with New Holes 37 Figure 13 : Double Takeoff Warning Switch Relocation with New Holes- Detail 38 Fi gure 14 : Flight deck Control Stand 42 Figure 15: Light Plate Removal 43 Figure 16: Light Plate Installation 44 Figure 17 : Light Plate Adjustment 45 Figure 18 : Light plate Removal 51 Figure 19 : Light Plate Removal 52 Figure 20: Light Plate Hole and Nutplate 53 Figure 21 : Light Plate Hole and Nutplate 54 Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 3 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 1. PLANNING INFORMATION A. EFFECTIVITY 1. Aircraft Affected All 737-700 and 737-700C (including C-40A) series airplanes with STC installed APB Blended Winglets. NOTE: 737-700 and 737-700C airplanes with TC installed APB Blended Wing lets must be addressed by Boeing service bulletin 737-27 A 1306. This service bulletin is effective for the airplanes shown below that have installed APB Blended Winglets in accordance with STC ST00830SE except 737-700 airplane line numbers 384 (YG033) and 3128 (YG124). 737-700 airplane line numbers 384 (YG033) and 3128 (YG124) must be addressed by APB service bulletin AP737 -34-005. This service bulletin effectivity is divided into 3 aircraft Groups according to the relevant configuration and the SB itself is divided into 5 PARTS. The SB PARTS are structured to allow their independent accomplishment. PART 1 is applicable to Group 1 and Group 3 only. PART 2 is applicable to Group 2 only. PART 3 is applicable to Group 1 and Group 2 only. PART 4 is applicable to Group 1, 2 and 3. PART 5 is applicable to Group 3 only. Software updates in PART 4 may be accomplished prior to hardware modifications in PART 1, 2, 3 and 5. Group 1 aircraft are manufacturing line number 1 through 3099 (not including Group 3 aircraft) configured with a single horizontal stabilizer position limit and warning switch (S132). Group 2 aircraft are manufacturing line number 3100 and on configured with double horizontal stabilizer position limit and warning switches (S 132 and S1184). Group 3 aircraft are 737-7001GW (BBJ) line number 101 through 684 that have OEM light plates that have not been replaced by APB light plates in accordance with APB service bulletin APB737 -27-001. Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 4 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737 -27-002 GROUP Airplane Model Top Collector Winglet Kit Configuration 737-700 737-7000-1 ' 737-7000-3, 737-7000-5, 737-7003-1 ' 737-7003-3, 737-7003-7, 1 737-7005-1 ' 737-7005-3, 737-7006-1' 737-7006-5, 737-0000-1 (Not Including Group 3 aircraft) 737-0100-1 , 737-0100-3 737-700C 737-7002-1' 737-7002-5, 737-7004-1 2 737-700 737-7005-3, 737-7005-5 3 737-700 737-0000-1 Group 3- Airplane Model: 737-700 IGW (BBJ) that have been included in the effectivity of APB service bulletin AP737-27-001 as follows but have not been modified in accordance with APB service bulletin APB737-27-001. Line Number 101 126 146 150 167 179 189 265 280 348 432 516 602 684 2. Spares Affected None . Customer Variable YG001 YG003 YG006 YG007 YG009 YG010 YG011 YG022 YG023 YG030 YG024 YG068 YG071 YG074 B. CONCURRENT REQUIREMENTS None Original Issue: March 31 , 2015 Revision 4: April 24, 2017 Serial Number 29102 28581 29273 29251 29142 30076 29139 29317 29268 29149 29269 30754 30789 29971 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 5 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 C. REASON 1. Background Recent analysis of the trim control system has shown that the 737-700 with Blended Winglets are not compliant with 14CFR 25.107(e) (4) in worst case conditions. The nose-up pitch trim limit (green band and warning horn) for blended winglet equipped 737-700s is set too far aft. 2. Safety Intent The safety intent of th is service bulletin is to correct the nose-up pitch trim limit location, which , if not corrected , could make the airplane uncontrollable during take-off if the flight crew mistrims to the full nose-up position when the aircraft is in an aft-light loading condition at critical flap settings. (14CFR25 requires that the airplane remain controllable in mistrimmed conditions). The incorpo ra tion of this service bulletin w i ll ensure that the nose-up pitch trim w i ll be set within safe limits for take-off. 3. Configuration Description This service bulletin gives instructions to replace the control stand stabilizer trim light plates in the flight compartment with one that has smaller greenband limits and to change the location of the nose-up take-off warning limit switches. This service bulletin also gives instructions to install new Flight Management Computer (FMC) Model/Engine Database (MEDB) software, wh ich includes revised take-off settings due to the smaller greenband limits. Original Issue: March 31 , 2015 Revision 4: Apri124, 2017 Aviation Partners Boeing PROPRIETARY AP737-27-002 Page 6 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 D. DESCRIPTION This service bulletin provides instructions to replace flight deck control stand pitch trim light plates, and to relocate the horizontal stabilizer position warn ing horn switch(es). This service bulletin also provides instructions for the software changes in the Model/Engine Database (MEDB) portion of Flight Management Computer (FMC). Group 1: Relocate a single horizontal stabilizer position limit and warning switch (8132), replace flight deck control stand pitch light plates, and update FMC software. Group 2: Relocate double hor izontal stabilizer position limit and warning switches (8132 and 81184) , replace flight deck control stand pitch light plates, and update FMC software. Group 3: Relocate a single horizontal stabilizer position limit and warning switch (8 132), replace OEM flight deck control stand pitch light plates, and update FMC software. The work in this service bulletin is done in the ma intenance zone(s) given below. Affected Maintenance Zones Zone Area 211 Flight Compartment - Left 212 Flight Compartment- Right 311 Area Aft of Pressure Bulkhead - Left 312 Area Aft of Pressure Bulkhead - Right Original Issue: March 31 , 2015 Revision 4: April24, 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 7 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 /; , I I I If ("-, / I / l \ '"'/ II "' \ I I \ ',"' :/ /~ \ ', I / ,,..--___ __ \\ "'','- /~..-::../~.... L.. -- - -=----==---">('\. .. / .!/.. JJ' HORIZONTAL STABILIZER \ '\. /.. , TRIM LIMIT SWITCHES \ '-< _. /' .. / ' \ ''----/.. /" ACCESS DOOR TO \ ... .-" AF T UNPRESSURIZED /Vj /// / COMPAR TME NT , 311BL /;;?',/"'./ / / ·-- / / ::----.. . .. ____ ~ .v· _,. ---z.. __ -. / ~~~ jl,' --------... , / I ..,."" ,/~ ------- 7,/ ~ ,....,--- - -....-'~ .....:1--~- - ------ - ------/'/ L~- <:PANEL ()_// --- ~ COCKPIT CONTROL STAND Original Issue: March 31 , 2015 Revision 4: April 24. 2017 Figure 1: Areas of Work Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 8 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 E. 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. Aviation Partners Boeing recommends that owners/operators accomplish this modification within 72 months after the issue date of revision 1 of this service bulletin. F. APPROVAL This service bulletin has been reviewed by the Federal Aviation Administration (FAA). The repairs and modifications contained herein comply with the applicable Federal Aviation Regulations (FAR) and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASAIJAA approved airplanes listed in the service bulletin effectivity. Th is service bulletin and its approval were based on the airplane as modified by APB winglet retrofit in accordance with STC ST00830SE. If an airplane has any other non-Boeing modification or repair that affects a component or system also affected by this service bulletin, the operator is responsible for obtaining appropriate regu latory agency approval before incorporating this service bulletin. G. WARRANTY INFORMATION Boeing warranty remedies are available for airplanes with winglets in warranty per the applicable Blended Wing let System Sales Agreement as of June 8, 2015. (Typically within 48 months of the delivery of airplanes with factory installed wing lets, or 48 months from the delivery of retrofit wing lets). For man- hour and material reimbursement for airplanes in warranty as of the foregoing date, send a warranty claim to Boeing Warranty & Product Assurance Contracts. H. MANPOWER The table below shows an estimate for the man-hours necessary to accomplish this service bulletin for each aircraft. This estimate is for direct labor only, done by experienced personnel. Adjust the estimate with operator man-hour data as necessary. This estimate does not include lost time. These are some examples of lost time: • Time to adjust to the workplace . • Time to sc hedule the wor k. • Time to inspect the work. • Time to cure the materials. • T im e to make the parts. • Time to find the tools. Original Issue: March 31, 2015 Revision 4: April 24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 9 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 Table 1 - Manpower PART 1 - RELOCATE SINGLE HORIZONTAL STABILIZER POSITION WARNING HORN SWITCH Task Number of Man-Hours Elapsed Time Persons (Hours) Access 1 1 1 Modificati ons 1 1.5 1.5 TOT AL FOR EACH SHIPSET 2.5 2.5 NOTE: Hours do not include removi ng electrical power from the airplane. PART 2 - RELOCATE DO UBLE HORIZONTAL STABILIZER POSITION WARNING HORN SWITCHES Task Number of Man-Hours Elapsed Time Persons (Hours) Access 1 1 1 Modifications 1 3 3 TOTAL FOR EACH SHIPSET 4.0 4.0 NOTE: Hours do not include removing electrical power from the airplane. PART 3- REMOVE AND REPLACE FLIGHT DECK CONTROL STAND PITCH TRIM LIGHT PLATES Task Number of Persons Rework 1 Perform a 1 functional test TOTAL FOR EACH SH IPSET Original Issue: M arch 31, 2015 Revision 4: Apri124, 2017 Man-Hours 2 1 3.0 Aviation Partners Boeing PROPRIETARY Elapsed Time (Hours) 2 1I 3.0 AP737 -27-002 Page 10 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 Table 1- Manpower (Continued) PART 4- REVISE FLIGHT MANAGEMENT COMPUTER (FMC) SOFTWARE Task Number of Man-Hours Elapsed Time Persons (Hours) Install new 1 1 1 MEDB software Perform a 1 1 1 functional test TOTAL FOR EACH SHIPSET 2.0 2.0 PART 5- REMOVE AND REPLACE OEM FLIGHT DECK CONTROL STAND PITCH TRIM LIGHT PLATES Task Number of Persons Install light plates 1 TOTAL FOR EACH SHIPSET I. WEIGHT AND BALANCE CHANGES Not changed. J. ELECTRICAL LOAD OAT A Not changed. K. REFERENCES 1. Existing Data: Man-Hours Elapsed Time (Hours) 3 3 3.0 3.0 a. D633A 101 -( XXX) Boeing 737-600/700/800/900 Aircraft Maintenance Manual (AM M). (XXX) Refers to customer specific code, subjects: 20-15-01 , 20-15- 11 , 27-41-00, 27-41-94, 31-51 -02, 33-18-00, 34-61 - 00, 76 -11-03. b. D634A201 Boeing 737-700 Structura l Repair Manual (SRM), 51-40-02, 51-40-03, 51-40-04, 51 -40-05. c. D634A330 Boeing 737-700 IGW SRM, 51 -20- 01 , 51 -40 -02, 51 -40-03, 51 -40-04, 51-40-05. Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 11 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 d. D634A202 Boeing 737-700 Convertible SRM, 51-40-02, 51-40-03, 51-40-04, 51-40-05. e. Boeing Standard Overhaul Practice Manual (SOPM), 20-41-02, 20- 43-03. f. BAC5004-1 Solid Rivet Installation g. BAC5719 Chemical Conversion Coatings for Aluminum and Aluminum Alloys h. BAC5736 Application of Chemical and Solvent Resistant Finishes 2. Data Supplied with This Service Bulletin: None 3. Installation Drawings Used in the Preparation of This Service Bulletin: Drawing Number 737-7960 737-7961 737-0840 737-7840 737-7841 Title lnstl- Limit & Warning switch mod, Stabilizer trim lnstl - Control Stand Modification Configuration and Functional Test- Flight Management Computer, 737-BBJ Configuration and Functional Test - Flight Management Computer, 737-700 Configuration and Functional Test- Flight Management Computer, 737-700C These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 12 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737 -27-002 L. PUBLICATIONS AFFECTED 1. Publications: Publication AP37.1-0600, APB Supplement to 737-700 IGW BBJ Aircraft Maintenance Manual AP37.7-0618, APB Supplement to 737-700 IGW BBJ Aircraft Maintenance Manual AP37.7-0600, APB Supplement to 737-700 Aircraft Maintenance Manual AP37 .7-0622, APB Supplement to 737-700C Aircraft Maintenance Manual AP37 .1-0601 , 737-700 IGW Airplane Flight Manual Supplement AP37.1-0616, 737-700 IGW Ai rplane Flight Manual Supplement AP37 .7-0601 , 737-700 Ai rplane Flight Manual Supplement AP37.7-0616, 737-700C Airplane Flight Manual Supplement AP37 .7-0614, APB Supplement to 737-700 Aircra ft Illustrated Parts Catalog AP37.7-0625, APB Supplement to 737-700C Aircraft Illustrated Parts CataloQ AP37.1-0802, Instructions for Continued Airworthiness- APB Winglets STC ST00830SE D638A001 , Aircraft Illustrated Parts Catalog Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Chapter I Section 27-41-00, 31-51-02 27 -41 -00, 31-51-02 27-41-00, 31-51 -02 27-41-00, 31-51-02 SECTION 3 Flight Management Computer System SECTION 4 Recommended Takeoff Stabi li zer Setting SECTION 3 Flight Management Computer System SECTION 4 Recommended Takeoff Stabilizer Setting SECTION 3 F li ght Management Computer System SECTION 4 Recommended Takeoff Stabilizer Setting SECTION 4 Recommended Takeoff Stabilizer Settin_g_ 76 -11 -03 76-11-03 Section 1 Introduction 34-61-00 AP737 -27-002 Page 13 of 54 Aviation Partners Boeing PROPRIETARY AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 2. Damage Tolerance Based Structural Inspections: APB has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore no new OT is are necessary. M. INTERCHANGEABILITY AND INTERMIXABILITY OF PARTS Refer to Paragraph 2.8., Parts Necessary for Each Airplane, for in terchangeability and intermixability information. N. SO FT WA RE ACCOMPLISHMENT SUMMARY 1. System affected by this change: Fl ight Management Computer (FMC) 2. Software changes which affect operational procedures: None. 3. Other software improvements: FMC will display the updated nose-up pitch trim limit. Original Issue: March 31 , 2015 Revision 4: April 24, 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 14 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 2. MATERIAL INFORMATION A. MATERIAL - PRICE AND AVAILABILITY Price and availability of material required to accomplish this service bulletin are as described in Paragraph 2.8 , below. B. PARTS NE CE SSARY TO CHANGE EAC H AIRPL AN E Parts and materials necessary to accomplish th is bulletin are shown in Table 3 and 4, below. 1. Parts Available from APB Required parts are shown in Table 2. These parts should be obtained from APB via Purchase Order to aogspares@aviationpartners.com. Contact APB at the same address for current pricing and availabi li ty. Table 2 - Parts Ava il able from APB Material Description QTY per SS Note Replaces 737-8618-1 737-8618-3 Li ght Plate 1 (Group 1 Ai rcraft) Replaces 737-8618-724 (Group 3 Aircraft) Replaces 73 7-8618-2 737-8618-4 Light Plate 1 (Group 1 Aircraft) Replaces 737-8618-725 (Group 3 Aircraft) 2. Parts and Mate ri al Supplied by aircraft owner/operator Aircraft owner/ operators are responsible for furnishing the material identified in this subparagraph. Table 3 - Parts and Material Su pplied by the Aircraft Owner/Operator Material BACR15885AD4 BACR15CE5AD4 BACN10JN04 BACR15DR3AC1 NAS1149DN416J Original Issue: March 31 , 2015 Revision 4: April 24, 2017 Description Rivet Rivet Nutplate Rivet Washer Aviation Partners Boeing PROPRIETARY QTY per SS As req uir ed As required As required As required As required AP737 -27-002 Page 15 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 Material Description QTY per SS MS20995NC20 Lock Wire 1 Roll MS20995NC32 Lock Wire 1 Roll BMS 10-11, Type I Primer 2 ounces BMS3-38 (Preferred) Corrosion Inhibiting 2 ounces BMS3-27 (Alternate) Material Alodine 600 Conversion coating 2 ounces Table 3 - Parts and Materials Supplied by the Operator/Operator (Continued) Disk Set Title Disk Set P/N Software PIN Notes 34 FMC MEDB 242A6020-1 032 BCG-01T-AO (a) (b) (c) (a) This software part number is used in production. Operators may already have th is media set. (b) Only one media set is necessary for each operator. (c) Get the MEDB disk set from Boeing Spares. Refer to this service bulletin number in the purchase order. 3. Parts Modified and Re-identified The parts shown below are changed as shown in this service bulletin. Quantity is the number of parts changed on each airplane . G 3 roup only: Existing Part RUC Name QTY New Part PNC Number Number 65C31525 RWK Bracket 1 - N 65C31526 RWK Bracket 1 - N RUC Recommended Use Code RWK Make the change as specified in this service bulletin. RPC A A Original Issue: March 31 , 2015 Revision 4: April24 , 2017 AP737 -27-002 Page 16 of 54 Aviation Partners Boeing PROPRIETARY AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 PNC Part Number Code N There is no equivalent APB part number for the changed part. Identi fy on the part that the change given in this service bulletin was made. RPC Replacement Code A Do not use the existing part to replace the new or changed part. 4. Parts Removed and Not Replaced None 5. Parts Removed and Replaced The parts shown below are removed and replaced as shown in this service bulletin. Quantity is the number of parts changed on each airplane. Existing Part RUC Name QTY New Part PNC RPC Number Number 737-8618-1 DIS Light Plate 1 737-8618-3 s 737-8618-2 DIS Light Plate 1 737-8618-4 s RUC Recommended Use Code DIS Discard the part. Keep the part if there are other uses for it. PNC Part Number Code S This is the part number for the new equivalent or replacement part. To get a new part, use this part number in your order. RPC Replacement Code A A A Do not use the existing part to replace the new or changed part. C. SPECIAL TOOLING- PRICE AND AVAILABILITY Special tools are required to perform modifications in this service bulletin. Contact APB for tool price and availability. Original Issue: March 31 , 2015 Revision 4: April 24, 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 17 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 D. SPECIAL TOOLING NECESSARY TO DO THIS SERVICE BULLETIN See Table 4 for required special tooling . Aircraft with retrofit wing lets will not require a drill jig fixture. Since the nose-up horizontal stabilizer position warning horn switch position reverts to its original hole location on airplanes delivered without wing lets, no new holes will be required. Aircraft with factory installed wing lets will require a drill jig fixture to establish the new switch location. Table 4- Special Tooling Necessary to Do This Service Bulletin Tool Number TE27T -41 001-8 or F80055-1 DJ-737-7960-9L Original Issue: March 31, 2015 Revision 4: April24, 2017 Name QTY Measuring Bar Tool 1 or Trammel Bar Drill Jig Fixture 1 Aviation Partners Boeing PROPRIETARY Airplane Group Group 1, 2 and 3 Group 1, 2 and 3 AP737 -27-002 Page 18 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL NOTES WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE CAN OCCUR. CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES, OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE TO THE AIRPLANE OR EQUIPMENT. NOTE: 1. Obey all warnings and cautions given in the applicable sections of the 737-700 Aircraft Maintenance Manual (AMM). 2. Unless shown differently, these dimensions and tolerances are used: - All linear dimensions, areas, volumes, temperatures, pressures, weights, and energy will show U.S. Customary Units. - Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus or minus 0.03 inch. - Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch. - Angular tolerance is plus or minus 2 degrees. Hole dimensions for standard solid rivets are given in the 737 Structural Repair Manual (SRM), 51-40-05. - Torque limits to tighten nut and bolts are given in the 737 SRM, 51-40-04. 3. Make the following entry into the aircraft's records once service bulletin is completed: "Aviation Partners Boeing Service Bulletin AP737-27-002 completed on (date) by (name of individual or company)." 4. For approved fastener and process material substitutions, refer to the 737 SRM, chapter 51 and Boeing drawing 65-88700. Alternate fasteners are given in the 737 SRM, 51-40-03 and Boeing drawing 65-88700. Original Issue: March 31 , 2015 Revision 4: April24, 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 19 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 5. If the length of any fastener specified in this service bulletin does not meet the installation standards in 737 SRM, 51-40-02, then a fastener of the same specification or an approved substitute, with a length which meets the installation standards in the 737 SRM, 51-40-03 may be used. 6. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 7. Refer to 737-600/700/800/900 AMM 20-15- 11 for on-airplane software installation maintenance practices, as an accepted procedure. 8. Refer to 737-600/700/800/900 AMM 20-15-01 for off-airplane software installation maintenance practices, as an accepted procedure. 9. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the document must be used. 10. The work in structions are divided into PARTS. Task Hours and Elapsed Hours for each package are given in Paragraph.1.H. You may accomplish each PART independently. 11 . Some steps in the Work Instructions are identified as Required for Compliance (RC). If this service bulletin is mandated by an airworthiness directive (AD), then the steps identified as RC and steps indented under an RC step must be done to comply with the AD . Alternative procedures for steps not identified with RC can be used if the RC steps and indented steps can still be done as specified, and the airplane can be put back in a serviceable condition. An Alternative Method of Compliance (AMOC) is not necessary for deviations to steps that are not identified as RC. Original Issue: March 31 , 2015 Revision 4: April24 , 201 7 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 20 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 B. WORK INSTRUCTIONS PART 1- RELOCATE SINGLE HORIZONTAL STABILIZER POSITION WARNING HORN SWITCH Refer to Figure 2 for the work flow. Note: The diagram only supplements the information in the accomplishment instructions and is not intended to serve as the primary source for tasks in this SB. 1. Set the stabilizer trim cutout switches to the CUTOUT position. 2. Open these circuit b re akers and install safety tags: • F/0 Electrical System Panel, P6-2 Row Col Number Name B 10 C00207 FLIGHT CONTROL STAB TRIM CONT • F/0 Electrical System Panel, P6-3 Row Col Number Name c 18 C01398 LANDING GEAR TAKEOFF WARNING CUTOFF D 18 C00451 LANDING GEAR AURAL WARN 3. Open th is access panel. Refer to Figure 3: • Stabilizer Trim Access Door 311 BL 4. Adjust the stabilizer "B" dimension to 24 inches+/- .01 inch. Refer to Figure 4. 5. Remove S132 switch and mark it as "8132", leaving wire harness attached. Salvage all hardware except lock wires and keep reusable parts (hardware). Refer to the 737-600/700/800/900 AMM , 31-51-02 for the removal of the S132 switch as an accepted procedure. CAUTION: Excessive axial tension loads on the switch shaft can result in internal damage to the switch. 6. Locate an existing open hole for S 132 switch approximately 1.5 inches above the current location of S132 switch. Refer to Figure 5. Condition 1: If the open hole exists, do steps 7, 8 and 9 and go to step 13. Condition 2: If the open hole does not exist, drill new holes in accordance with steps 10 through 12. 7. RC for Condition 1, Group 1 and Group 3 aircraft - Drill two new holes in accordance with Figure 6. Original Issue: March 31 , 2015 Revision 4: April 24, 201 7 Aviation Partners Boeing PROPRIETARY AP737-27-002 Page 21 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 8. Remove two rivets next to the open hole. Countersink resulting holes on both sides of web to a depth of .015 - .020 X 100 deg. Refer to Figure 6. Install BACR15CE5AD4 rivets. Refer to BAC5004-1 or 737-700 SRM, 51-40-02 as an accepted procedure. Microshave manufactured head and formed head flush within +0.005, -0.000 inch after installation. Refer to BAC5004-1 as an accepted procedure. 9. Manually apply Alodine 600 to bare surfaces including shaved rivet. Refer to BAC5719 or SOPM 20-43-03 as an accepted procedure. Apply one coat of BMS 10-11, Type I primer. Refer to BAC5736 or SOPM 20- 41 -02 as an accepted procedure. Sk ip steps 10 through 12 and go to step 13. 10. Remove S144 switch and mark it as "S144", leaving wire harness attached. Salvage all hardware except lock wires and store. Refer to the 737- 600/700/800/900 AMM, 27-41-94 for the removal of the S144 switch as an accepted procedure. CAUTION: Excessive axial tension loads on the switch shaft can result in internal damage to the switch. 11 . Locate drill jig fixture DJ-737-7960-9L and check lower switch hole location S144 using tooling check pin. 12. RC for Condition 2, Group 1 and Group 3 ai rcraft- Drill three new holes in accordance with Figure 7 and 8. 13. Open up two index holes next to the current S 132 switch hole to .159 - .167 dia. Install BACR 15BB5AD4 rivets. Refer to Figure 8. Refer to BAC5004-1 or 737-700 SRM, 51-40-02 as an accepted procedure. 14. RC for Group 1 and Group 3 ai rc raft - Install S 132 switch in the new location. Re-install S144 switch in the original location if removed in step 10. lnstaii32EN21-4 switch assembly in bracket with BMS3-38 (BMS3-27 acceptable alternate) corrosion inhibiting material. Orient lead wires as shown +!- 5 degrees. Orient switch arm as shown. Adjust S132 switch. Refer to 737- 600/700/800/900 AMM TASK 31-51-02-820-801 as an accepted procedure. Adjust S 144 switch if removed in step 1 0. Refer to 73 7-600/700/800/900 AMM TASK 27-41-94-820- 801 as an accepted procedure. Refer to the 737- 600/700/800/900 AMM , 31-51-02 for the installation of switch S132 as an accepted procedure and 737-600/700/800/900 AMM , 27-41 -94 for the installation of switch S144 as an accepted procedure. CAUTION: If adjustments are to be completed at a later time, switch arms should be placed in a position clear of the cam throughout the entire range of cam motion. Original Issue: March 31, 2015 Revision 4: April 24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 22 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 15. Remove the safety tags and close these circuit breakers: • F/0 Electrical System Panel, P6-2 Row Col Number Name B 10 C00207 FLIGHT CONTROL STAB TRIM CONT • F/0 Electrical System Panel, P6-3 Row Col Number Name c 18 C01398 LANDING GEAR TAKEOFF WARNING CUTOFF D 18 C00451 LANDING GEAR AURAL WARN 16. Close this access panel. Refer to Figure 3. • Stabilizer Trim Access Door 311 BL 17. Set the stabilizer trim cutout switches to the NORMAL position. 18. Put the airplane back to a serviceable condition. Original Issue: March 31 , 2015 Revision 4: April 24, 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 23 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 YES Step 1 - Set the stabilizer t ri m cutout switches to CUTOUT. Step 2 -Open the circuit breakers. Step 3 - Open the access panel. Step 4 -Adjust t he B dimension. Step 5- Remove switch S-132. NO Step 7 - Drill 2 hol es . Step 10- Remove switch S-144. Step 8 - Remove 2 rivets and plug the holes. Step 11 -Locate drill jig fixture. Step 9 - Touch up finish. Step 12 - Drill 3 holes. Step 13- Open up 2 holes and plug the holes. Step 14 -Install removed switch(es ). Step 15- Close the circuit breakers. Step 16 - Close the acce ss p an el. Step 17- Set the stab il izer trim cutout switches to NO RM AL. Note: This diagram on ly supplements the information in the accomplishment instructions and is not intended to serve as the prima ry source for tasks in this S B. Original Is sue: March 31 , 2015 Revision 4: April24 , 2017 Figure 2: PART 1 Work Flow Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 24 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737 - 27 -002 ~ '--- --- a ~.::..---ACCESS DOOR TO ~ , AFT UN PRES SU RIZED COM PART ME NT , 31 1 BL S EE A FWD ~ VIEW THROU GH THE ACC E SS DOOR TO AFT UNPRE SS URI Z ED CO MP A RT M ENT , 31 1BL 0 Figure 3: Access to S tab ili zer Takeoff Warn ing Switc h Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY Figure 4 AP737 -27-002 Page 25 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 STABILIZER TR IM ACTUATOR NOTE: The stabilizer trim jackscrew is shown with the stabilizer leading edge at zero degrees. E) The dimension B is measured between the center of the upper and lower gimbal pins, (center of grease fittings). ACTUATOR TRAMMEL BAR DIMENSION B [L) FWD!/) Figure 4: Stabilizer Takeoff Warning Switch "B" Dimension Definition Original Issue: March 31, 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY AP737-27-002 Page 26 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737 -27-002 .. 4 36 (s. m aJ Existing Hole " 6 " 9' New S 132 Loca tion Arm See Figure 6 Lead Wire Direction ~; ---------;-~~~~--------------------------------~~ NOTE: Th e dimensions apply with B-Dimension at 24 +/- 0 .0 1 inches. Figure 5: Single Takeoff Warning Switch Relocation with an Existing Hole Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 27 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 STA (2 . 5445) {2 . 3210) I I (4. 4 36 1 I {5.9368) ~ \ Step 8 \ 0.4700 REF Step 7 2X 0. 1450 - . 1 500 {s 00 . ooso ®\ c ®] t\ Step 13 NOTE: The dimensions apply with 8-Dimension at 24 +/- 0. 01 inches. Figure 6: Single Takeoff Warning Switch Relocation with an Ex isting Hole - Detail Original Issue: March 31 , 2015 Revision 4 April 24, 2017 Aviation Partners Boeing PROPRIETARY AP737-27-002 Page 28 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 4 C Jb (~ . 9J68) n& ' ' " Ne w S1 32 Location Arm NOTE: The dimensions apply with 8-Dimension at 24 +/- 0. 01 inches. See Figure 8 Lead Wire Direction -----~ ~ Figure 7: Single Takeoff Warning Switch Relocation with New Holes Original Issue: March 31 , 2015 Revision 4. April 24, 201 7 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 29 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP7 37-27-002 STA [ 4. 4 36 ] (5 . 9368) (2. 5 44 5) [ 2. 3210 \ I I I ~ \ \ St e p 12 0 .468 5- . 4 715 - o.0150 A B •c t\ S tep 12 2X 0 . 1450- . 1500 {]f_~ i> ..:. oo5o ~l c ~ \,\ Step 13 NOTE: The dimensions apply with 8-Dimension at 24 +/- 0.01 inches. Figure 8: S in gle Takeoff Warning Switch Relocation with New Ho les- Detail Original Issue: March 31 , 2015 Revision 4: April 24 , 2017 Aviatton Partners Boetng PROPRIETARY AP737 -27-002 Page 30 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 PART 2- RELOCATE DOUBLE HORIZONTAL STABILIZER POSITION WARNING HORN SWITCHES Refer to Figure 9 for the work flow. Note: The diagram only supplements the information in the accomplishment instructions and is not intended to serve as the primary source for tasks in this SB. 1. Set the stabilizer trim cutout switches to the CUTOUT position. 2. Open these circuit breakers and insta ll safety tags: • F/0 Electrical System Panel, P6-2 Row Col Number Name B 10 C00207 FLIGHT CONTROL STAB TRIM CONT • F/0 Electrical System Panel, P6-3 Row Col Number Name c 18 C01398 LANDING GEAR TAKEOFF WARNING CUTOFF D 18 C00451 LANDING GEAR AURAL WARN 3. Open this access panel (Refer to Figure 3): • Stabilizer Trim Access Door 311 BL 4. Adjust the stabilizer "B" dimension (Refer to Figure 4) to 24 inches +/- .01 inch. 5. Remove S132 and S1184 switches and mark them as "S132" and "S1184" respectively, leaving wire harness attached. Remove 3/16 locking nut, 3/16 flat washer, switch arm, 15/32 jam nut, and internal tooth lock washer from 32EN21-4 switch assemblies. Salvage all hardware except lock wires and store. Refer to the 737-600/700/800/900 AMM, 31-51-02 for the removal of the S 132 and S 1184 switches as an accepted procedure. CAUTION: Excessive axial tension loads on the switch shaft can result in internal damage to the switch. 6. Locate the existing open holes for S 132 and S 1184 switches approximately 1.5 inches above the current location of S 132 and S 1184 switches. (Refer to Figure 10) If the open holes exist, do steps 7, 8, and 9 and go to step 13. If the open holes do not exist, drill new holes in accordance with steps 10 through 12. 7. RC for Group 2 ai rcraft- Drill four new holes in accordance with Figure 11 . Original Issue: March 31 , 2015 Revision 4: April24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 31 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 8. Remove two rivets next to the open holes. Countersink resulting holes on both sides of web to a depth of .015 - .020 inch X 100 deg. Install BACR15CE5AD4 rivets. Refer to BAC5004-1 or 737-700 SRM, 51-40- 02 as an accepted procedure. Microshave manufactured head and formed head flush within +0.005, -0.000 inch after installation. Refer to BAC5004-1 as an accepted procedure. 9. Manually apply Alodine 600 to bare surfaces including shaved rivet. Refer to BAC5719 or SOPM 20-43-03 as an accepted procedure. Apply one coat of BMS 10-11 , Type I pr imer. Refer to BAC5736 or SOPM 20-41-02 as an accepted procedure. Skip steps 10 through 12 and go to step 13. 10. Remove S144 switch and mark it as "S144 ", leaving wire harness attached. Remove 3/16 locking nut, 3/16 flat washer, switch arm, 15/32 jam nut, and in ternal tooth lock washer from 32EN21-4 switch assembly. Salvage all hardware except lock wires and store. Refer to the 737-600/700/800/900 AMM , 27-41-94 for the removal of the switch as an accepted procedure. CAUTION: Excessive axial tension loads on the switch shaft can result in internal damage to the switch. 11. Locate drill j ig fixture DJ -737-7960-9L and check lower switch hole location S144 using tooling check pin. 12. RC for Group 2 aircraft- Drill six new holes in accordance with Figure 12 and 13. 13. Open up two index holes each next to the current S 132 and S 1184 switch holes to .159- .167 dia. Install BACR15BB5AD4 rivets. Refer to BAC5004-1 or 737-700 SRM, 51-40-02 as an accepted procedure. Refer to Figure 13. 14. RC for Group 2 aircraft -Install S132 and S1184 switches in the new locations. Re-install S144 switch in the original location if removed in step 10. Install 32EN21-4 switch assemblies in bracket with BMS3-38 (BMS3-27 acceptable alternate) corrosion inhibiting material. Orient lead wires as shown +/- 5 degrees. Orient switch arm as shown. Adjust S132 and S1184 switches. Refer to 737-600/700/800/900 AMM TASK 31-51-02-820-801 as an accepted procedure. Adjust S144 switch. Refer to 737-600/700/800/900AMM TASK 27- 41-94-820-801 as an accepted procedure. Refer to the 737-600/700/800/900 AMM , 31-51-02 for the installation of switch S132 and switch S1184 as an accepted procedure and 737-600/700/800/900 AMM , 27-41-94 for the installation of switch S144 as an accepted procedure. CAUTIO N: If adjustments are to be completed at a later time, switch arms should be placed in a position clear of the cam throughout the entire range of cam motion. Original Is sue: March 31 , 2015 Revision 4: April 24, 2017 Aviation Partners Boeing PROPRIETARY AP737-27-002 Page 32 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737 -27-002 15. Remove the safety tags and close these circuit breakers: • F/0 Electrical System Panel, P6-2 Row Col Number Name B 10 C00207 FLIGHT CONTROL STAB TRIM CONT • F/0 Electrical System Panel, P6 -3 Row Col Number Name c 18 C01398 LANDING GEAR TAKEOFF WARNING CUTOFF D 18 C00451 LANDING GEAR AURAL WARN 16. Close this access panel. Refer to Figure 3. • Stabilizer Trim Access Door 311 BL 17. Set the stabilizer trim cutout switches to the NORMAL position. 18. Put the airplane back to a serviceable condition. Original Issue: March 31, 2015 Revision 4. April 24, 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 33 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737 -27-002 YES Step 1 - Set the stabilizer trim cutout switches to CUTOUT. Step 2- Open the circuit breaker. Step 3 - Open the access panel. Step 4 -Adjust the B dimension. Step 5 - Remove switch S-132 and S-1184. NO Step 7 - Drill 4 holes. Step 10 - Remove switch S-144. Step 8 - Remove 4 rivets and plug the holes. Step 11 - Locate drill jig fixture. Step 9- Touch up finish. Step 13- Open up 4 holes and plug the holes. Step 14- Install removed switches. Step 15- Close the circuit breaker. Step 16- Close the access panel. Step 12 - Drill 6 holes. Step 17- Set the stabilizer trim cutout switches to NORMAL. Note: This diagram only supplements the information in the accomplishment instructions and is not intended to serve as the primary source for tasks in this SB. Original Issue: March 31 , 2015 Revision 4: April 24, 2017 Figure 9: PART 2 Work Flow Aviation Partners Boeing PROPRIETARY AP737- 27-002 Page 34 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737 -27-002 25 1A4700 ' " .. 3eo t cs. 2130) New 51184 Location ( l6 7490 , Current 51184 Locatio n Switch Arm Direction I TYPICAL\ Current 5132 / I I nJ NOTE: The dimensions apply with 8-Dimension at 24 +/- 0. 01 inches. See Fig ure 11 Locat i on Lead Wire Direction ( TYP ICA L) Figure 10: Double Takeoff Warning Switch Relocation with Existing Holes Original Issue: March 31 , 2015 Revision 4. April 24 , 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 35 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 ( 3 . 7320 ) Step 7 2 ¢ . 1500 X . 1450 l-$- l¢ o. ooso®l o®l 0 . 76500 Step 8 Step 13 251A4705 REF 251A4700 Step 8 I II I0 . 76500 j Step 8 NOTE: The dimensions apply with B-Dimension at 24 +/- 0.01 inches. ( 4.4360 , Step 7 hx ¢ . 1soo ' . 1450 Step 13 Figure 11 : Double Takeoff Warning Switch Relocation with Existing Holes - Detail Original Issue: March 31 , 2015 Revision 4: April 24, 2017 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 36 of 54 AVIATION PARTNERS BOEING SERVICE BULLETIN AP737-27-002 ew 51~1~8~4---;~~--~~~~~~----~~~ yocatio n I Cu r·r ent t 16.74,0 I S1 1 84 Location Switc h Arm Current S132 NOTE: The dimensions apply with 8-D imension at 24 +/- 0.01 inches. See Figure 13 Location Lead Wire Di rection (TYPICAL) Figure 12: Double Takeoff Warning Switch Relocation with New Holes Original Issue: March 31 , 2015 Revision 4: April 24, 201 7 Aviation Partners Boeing PROPRIETARY AP737 -27-002 Page 37 of 54