b737 3 Documentation

Boeing
737−300/400/500
Documentation
B737−3 DOCUMENTATION
For training purposes only.
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DOCUMENTATION B737−300/400/500
DOCUMENTATION
For Training Purposes Only
FRA US/E WeR 3.3.05 Page: 1

DOCUMENTATION B 737−300/400/500
INTRODUCTION
INTRODUCTION
GENERAL
Introduction
This Training Manual introduces the various operating documents used to
handle the Boeing B737-300.
Documentation which is used for the Boeing B737 - model group is basically
the same but differs in the model orientated data.
FRA US/F do 10.04.98 Page: 2

INTRODUCTION
Airplane Maintenance Manual
AMM
Airplane Maintenance Manual
System TROUBLE Mainten. Removal Adjustment Inspection Cleaning Approved

SHOOTING Servicing
Description Practice Installation Test Check Painting Repairs
(TS)
Page Block Page Block Page Block Page Block Page Block Page Block Page Block Page Block Page Block
001-099 101−199 201-299 301-399 401-499 501-599 601-699 701-799 801-899
Wiring
WDM Chapters
Charts Wire List Ground L. Terminal L.
ATA 20 - ATA 91
Wiring Diagram Manual ATA 80 Equipment L. Splice L. Hookup List
AOM Volume I Volume II Volume III

Limitations System Airplane
Procedures Information Performance IPC
Airplane Operation Manual Checklists Data

Illustrated Parts Catalog
DISPATCH
DEVIATION
GUIDE
SSM (MML) SRM
System Schematic Manual Structure Repair Manual
Figure 1 Airplane Documentation
AIRPLANE MAINTENANCE MANUAL

GENERAL
Purpose In addition, as a convenience to the user:
This publication contains information required to service, trouble shoot, check, Chapter 49 is issued in two self−contained sets. The first set of Chapter 49
test, adjust,clean, repair, and replace all systems and equipment installed in pages cover the GTCP85−129 Series Engines; this set is followed another
airplanes listed herein normally requiring such action on the line or in the main- set of Chapter 49 pages which cover the APS2000 Engines.
tenance hangar. − For the first set of Chapter 49 pages all revised and reissued pages are
For shop maintenance of units there are seperate manuals. further identified by a sub−logo, GTCP85−129 SERIES ENGINES,
The Maintenance Manual also contains information on inspection and mainte- placed to the right of the Boeing logo.
nance of airplane structure; however, information on repair of airplane structure − The second set of Chapter 49 pages are further identified by a sub−logo,
is contained in the Structural Repair Manual. APS2000 ENGINES, placed to the right of the Boeing logo.
NOTE: THIS MANUAL IS PREPARED SPECIFICALLY TO COVER THE Power Plant chapters 70 thru 80 are further identified by a sub−logo,
BOEING AIRPLANES LISTED IMMEDIATELY FOLLOWING THIS CFM56 ENGINES, placed to the right of the Boeing logo.
INTRODUCTION. All chapters are further divided into sections and subjects.
IT CONTAINS INSTRUCTIONS AND INFORMATION APPLICABLE Each chapter, section, and subject is identified by an assigned number.
SOLELY TO THOSE SPECIFIC AIRPLANES.
A revised page may carry a new page code or the same page code, and it may
IT MAY ALSO CONTAIN INFORMATION SUPPLIED BY THE CU-
be dated prior to, the same as, or subsequent to, the date of the page it re-
STOMER, THE ACCURACY AND VALIDITY OF WHICH THE
places.
BOEING COMPANY ASSUMES NO RESPONSIBILITY.
Chapter Numbering
Basic Structure
Chapterization of the Maintenance Manual has provided a functional break-
The AMM has the following basic structure:
down of the entire airplane. The chapter breakdown numbering system uses a
Introduction three−element number (XX−XX−XX). It provides for dividing the material into
List of Effective Airplanes Chapters, Sections, and Subjects. The three elements of the indicator each
List of Service Bulletins contain two digits.
The chapter number (1st element) and the first number of the section number
Chapters.
(2nd element) are assigned by ATA Specification No. 100. Material which is
Manual Arrangement and Numbering System applicable to a system as a whole uses zeros in the 2nd and 3rd elements of
The AMM is divided into chapters and groups of chapters. Each group and the numbers, that is, the chapter number followed by ”−00−00.”
every chapter has a tab provided for ease of location. The chapterization sepa- For example: 78−00−00 (Exhaust) is used for general description information
rates the Maintenance Manual into the primary functions and systems of the which provides an outline breakdown of the sections in the chapter.
airplane. As a convenience for the customer, an ATA NUMBER CROSS REFERENCE
GUIDE is provided at the end of the introduction. This guide is a listing of all
LRU’s (i.e. R/I subjects) which have a different chapter−section for the WDM
(Wiring Diagram Manual).

2nd Element
3rd Element
1st Element
76 − 11 − 01
Chapter/System Subject/Unit
(Engine Controls) (Numbers 01 through)
Section/Subsystem (Power Control)

Numbers 1 through 9 are used in
the fourth digit positions to identify
sub−sub−system
Figure 2 Chapter Numbering

EFFECTIVITY AND CONFIGURATIONS

General They are not used for changes in procedures when the aircraft configuration
Airplane Maintenance Manual information effectivity is placed in the effectivity has not changed.
block located in the lower margin of each page. Configuration numbers (CONFIG) are only applied when there is a multiple
When a page applies to all airplanes, the word ALL will be found in the effectiv- configuration of page blocks applicable to a customer’s aircraft.
ity block. Configuration numbers are usually in ascending, sequential numerical order,
If the information does not apply to all airplanes, either customer effectivity i.e., CONFIG 1, CONFIG 2, CONFIG 3, etc.
codes or registration numbers will identify the effectivity.
Power Plant Chapters
A cross−reference tabulation of customer effectivity codes, line numbers, vari-
In the power plant chapters of the Maintenance Manual, the word ALL placed
able numbers, manufacturing serial numbers, and registration numbers im-
in the effectivity block on a page means that the page pertains to either all air-
mediately follows this introduction.
planes or all engines, whichever the case may be.
When customer effectivity codes are used to identify effectivity; if the effec-
When the effectivity is limited to a system or component that remains with the
tivity is open−ended, the last digits will be 999.
airplane during the power plant replacement, the effectivity is expressed in a
When registration numbers are used to identify effectivity; if the effectivity is manner described in the preceding paragraphs.
open−ended, the term AND ON will be used. The term AND ON indicates all
When a Maintenance Manual section, page, step or illustration is limited to an
airplanes with the listed registration number and all registration numbers
engine type or component, the effectivity is given using the engine model,
numerically greater.
physical difference, or part number.
Where the differences are distinguishable by physical characteristics (type−
of−equipment), the effectivity may be described physically without reference
to customer effectivity codes or registration numbers.
Effectivity differences are reflected within the text of the manual by lead−in ef-
fectivity statements at the beginning of paragraphs that limit the effectivity of
information contained in the paragraph.
When effectivity differences are extensive and the preceding method of reflect-
ing effectivity becomes cumbersome, thus distracting from the continuity of
subject matter, additional page blocks are added.

Some of these added page blocks are further identified by the addition of a
configuration number immediately above the page number.
A previously issued page block is reissued to incorporate the configuration
number.
Configuration numbers are issued at page block level only.
The use of configuration numbers is kept to a minimum, and they are only
used when a configuration change to the aircraft results in a major change to
the manual.

PAGE CODE
EFFECTIVITY 76−11−01
ALL Page 401
01
Nov 15/90
Non-Configuration Procedure Example
CONFIG 1
AIRPLANES WITHOUT
01.1 Page 401
THE XYZ SYSTEM
Jul 15/92
CONFIG 1 Procedure Example
CONFIG 2
AIRPLANES WITH THE 01.101 Page 401
XYZ SYSTEM Jul 12/99
CONFIG 2 Procedure Example

CONFIG 2
NOT USED 01.101 Page 401
Jul 12/99
CONFIG Not used Example AMM Introduction
Figure 3 Effectivity, Page Code and Configuration

PAGE BLOCKS
General Instructions outside designed subtopics
Each subject is page numbered within itself and the identification of each page Whenever general maintenance instructions do not fall within one of the desig-
is by both the subject number and the topic or subtopic page number. nated subtopics, the maintenance instructions will be provided in the 201 to
These identification numbers appear in the lower right corner of each page. 299 page block.
The subjects are divided into reasonably small topics and subtopics to enable If the 201 to 299 page block consists of only one such subtopic, the 201 to 299
the user to locate the desired information more readily. page block title will be Maintenance Practices plus descriptive information indi-
cating procedure content.
Topics
The topics as defined by ATA Specification 100 are
DESCRIPTION AND OPERATION,
TROUBLE SHOOTING, and
MAINTENANCE PRACTICES.
The subtopics as defined by ATA Specification 100 are
− SERVICING,
− REMOVAL/INSTALLATION,
− ADJUSTMENT/TEST,
− INSPECTION/CHECK,
− CLEANING/PAINTING, and
− APPROVED REPAIRS.
The page blocks for these topics and subtopics are shown in the figure below.
Normally, each subtopic is written as an individual topic; however, if all subtop-
ics for one subject are brief, they are combined into one topic entitled MAINTE-
NANCE PRACTICES and provided in the 201 to 299 page block.

Nomenclature Page Block

DESCRIPTION AND OPERATION (D&O) 1 to 99
TROUBLESHOOTING (TS) 101 to 199
MAINTENANCE PRACTICES (MP) 201 to 299
SERVICING (SERV) 301 to 399
REMOVAL INSTALLATION (R/I) 401 to 499
ADJUSTMENT / TEST (A / D) 501 to 599
INSPECTION (I / C) 601 to 699
CLEANING / PAINTING (C / P) 701 to 799
APPROVED REPAIRS (REP) 801 to 899
Figure 4 Page Blocks

Servicing information is also located within the other chapters of the AMM. The
AMM USAGE information is provided as a result of accomplishment of maintenance actions.
General Testing − Three Levels

The organizational breakdown of the AMM is shown in the figure below. Testing information is divided into three categories − Operational Test, Func-
All chapters of the AMM are grouped under four major headings. For locating tional Test, and System Test.
information, identify the group of chapters related to the desired information, Following are definitions of the three categories:
then identify the chapter within the group. Operational Test: That procedure required to ascertain only that a system
The Chapter Table of Contents lists all subsystems numerically. It also lists the or unit is operable. These tests should require no special equipment or faci-
Maintenance Practices, such as Adjustment/Test, etc. lities other than that installed on the aircraft and should be comparable to
The units are listed in alphabetical order using the key noun as the title of the the tests performed by the flight crews.
unit. It is not intended that the operational test of the unit shall meet the specifi-
cations and tolerances ordinarily established for overhaul or major mainte-
The page number and effectivity are listed for each section or subject for which nance periods.
data is provided.
Functional Test: That procedure required to ascertain that a system or
The maintenance topics have assigned page blocks, such as all 500 numbers unit is functioning in all aspects in accordance with minimum acceptable
are adjustment/test pages. system or unit design specifications. These tests may require supplemental
After the section or subject has been identified, the information can be located ground support equipment and should be more specific and detailed than an
within the chapter numerically per section/subject number. operational test.
It should contain all necessary information to perform proficiency tests to
Description and Operation
maintain system or unit reliability at an acceptable level, without reference
The description and operation portion of each chapter provides an explanation to additional documents.
of system by function, operation, configuration and control. Sufficient informa-
System Test: That procedure containing all adjustment specifications and
tion is provided for the maintenance personnel to understand the system
tolerances required to maintain system and/or unit performance at maxi-
construction and function.
mum efficiency and design specifications. It shall be self−contained and
Trouble Shooting may duplicate other tests. It is normally used at major maintenance periods
Trouble shooting charts and trees provide the information needed to identify, The operational and system tests are normally accomplished at the system
locate, and correct any fault that is predicted to occur on the airplane from time level. The general paragraph at the beginning of each adjustment/test block of
to time. pages (page 501 through 599) outlines the test sequence.
The functional test relates to component performance after installation and is

Servicing normally contained with the component maintenance practices.
Chapter 12 is entitled SERVICING. The recommendation to test or not test after a maintenance action is provided
at the end of the appropriate maintenance practices subtopic.
This chapter contains instructions for the replenishment of items such as fuel,
oil, hydraulic fluid, water, tire pressure, etc. The tanks and reservoir capacities The Operational Test, Functional Test, and System Test may include steps to
are indicated, as well as the standard specification and grade of material to be make sure that a system is operational or adjusted.
used. The chapter contains scheduled and unscheduled servicing applicable to These steps include references to procedures that maintenance personnel may
the whole airplane. need to do only if they have indications that the system is not serviceable or
adjusted.

MAINTENANCE
MANUAL
AIRCRAFT AIRFRAME STRUCTURE POWER PLANT

GENERAL SYSTEM GROUP GROUP
GROUP GROUP
CHAPTERS 5−12 CHAPTERS 20−49 CHAPTERS 51−57 CHAPTERS 70−80

AMM Introduction
Figure 5 Organizational Breakdown

TROUBLE SHOOTING
General If unwanted material such as paper or cloth are ingested into the ram air sys-
For the B737−300/400/500 there is no unique troubleshooting concept tem, they could restrict air flow through the system.
available. Inspection doors are provided in the ram air ducts forward of each heat ex-
Trouble Shooting procedures can be found in the sub-section of the affected changer for duct inspection.
system. If difficulty occurred during flight while flaps were in any position other than fully
− In the systems sub-section, it is the page block 101−199. retracted, do a check of the cooling system (AMM 21−51−00/501).
− The procedure can be If the system has tripped off without excessive temperature being recorded, the
thermal switches may be defective and should be checked.
a flow chart or
B. It is recommended that you review AMM 20−10−27/201 before you use
a simple table, recommending an action
heating equipment on system components.
( for inst. „RECOMMENDED ACTION or REMEDY“ or requesting a
certain action (for inst. „REPLACE“.
With some systems, like autopilot, there is a trouble shooting guide avail- 2. Equipment and Materials
able in the maintenance manual. A. Tempcal Multirange Thermocouple and Thermal Switch Tester − H294 with
− This test-results are not mentioned in the maintenance manual. BH 17336 probe.
− In this case, the test-result message is a so called CLEAR MESSAGE
you have to follow.
3. Trouble Shooting
For details see ATA chapter 22 .
A. Trouble shooting is provided for these faults:
Troubleshooting for the avionics systems is explained in the ATA-Chapter 22
(Autoflight). (1) RAM DOOR FULL OPEN light(s) will not come on when the airplane is on
the ground (Figure 101).
A table called FLIGHT DECK EFFECT PREFERRED ORDER OF FMS-BITES
recommends which BITE to run for a flight deck effect fault. (2) Ram air door stays open in cruise (RAM DOOR FULL OPEN light(s) stays
For details see ATA chapter 22 . on continuously) (Figure 102).
Figure 101
Sheet 1 − RAM DOOR FULL OPEN Light will not come on when the airplane
Troublshooting Example with table: is on the ground Effectivity: ...

The example shows how to trouble shoot problems with the Ram Air System. Sheet 2 − RAM DOOR FULL OPEN Light will not come on when the airplane
is on the ground Effectivity: ...
This system is sub-section 21−52.
1. General Figure 102

A. If a system trips off from overheat but without excess air supply, the ram air Sheet 1 − Ram Air Door stays open in cruise (RAM DOOR FULL OPEN Light
system should be suspected. Stays On Continuously) Effectivity: ...
Make sure that the ram air inlet and exhaust doors are open. Sheet 2 − Ram Air Door stays open in cruise (RAM DOOR FULL OPEN Light
Stays On Continuously) Effectivity: ...
FRA US/E-1 WeR / NM 9.5.05 Page: 12

THE METHODE IS TO FOLLOW

THE CHART WITH „IF“ OR „IF NOT“
AMM 21−52−00
Figure 6 Trouble Shooting

Trouble Shooting with table Example

Sometimes, for trouble shooting a table is used. Trouble shooting the navigation lights is best accomplished during adjustment/
test (33−43−00).
Trouble shooting requires that power be available and appropriate circuit break-
ers be closed.
Trouble shooting procedures are based on the assumption that wiring is OK
and electrical power is available.
If the corrective action in the procedure does not correct the problem, check
the wiring using the wiring diagram.
TROUBLE PROBABLE CAUSE ISOLATION PROCEDURE REMEDY
Navigation light Bulb burned out Replace bulb. Replace bulb,

inoperative or faulty switch If light operates, bulb Replace switch
was burned out.
If light still inoperative,
replace switch
Navigation Lights Trouble Shooting Chart

EXAMPLE FOR
TROUBLESHOOTING THE ”TR UNIT” LIGHT PREREQUISITES
UNSING A CHART:
ON THE P5−13 PANEL MAKE SURE THE AIRPLANE IS IN THIS CONFIGURATION:
COMES ON ELECTRICAL POWER IS ON (AMM 24−22−00/201)
NO
1 SET THE DC METER SELECTOR 21 REPLACE THE TR1
SWITCH ON THE P5−13 PANEL TO (AMM 24−21−31/401).
THE ”TR1” POSITION.
DOES THE DC AMMETER SHOW
MORE THAN 6 1 AMPS?
YES
NO
SWITCH TO THE ”TR2” POSITION. (AMM 24−21−31/401).
DOES THE DC AMMETER SHOW
MORE THAN 6 1 AMPS?
YES
NO

SWITCH TO THE ”TR3” POSITION. (AMM 24−21−31/401).
DOES THE DC VOLTMETER SHOW
28 6V DC?
YES
27 REPLACE THE P5−13 PANEL.
Figure 7 Trouble Shooting

FMS Trouble Shooting

For the Flight Management System (FMS), there are special trouble shooting
procedures.
The FMS is a combined flight control, guidance, and navigation system.
The FMS is comprised of five subsystems. The subsystems are as follows:
Flight Management Computer System (FMCS)
Digital Flight Control System (DFCS)
Autothrottle (A/T) System
Inertial Reference System (IRS)
Electronic Flight Instrument System (EFIS).
The FMS BITE is initiated and controlled through the FMCS Control Display
Unit (CDU).
The FMCS CDU acts as the focal (single control point) unit, for actuating and
evaluating FMCS, DFCS, A/T, IRS, and EFIS BITE. When the airplane is on
the ground, the BITE tests are available to maintenance personnel.
The trouble shooting procedures and the BITEs of the FMS subsystems will be
discussed with the related systems.
In the AMM, the procedures are in chapter 22 “Auto Flight“.

FMCS BI TE 1/ 1
<I NFLT FAULT
<CDU TEST
<SENSORS PERF FACTR>
<DI SCRETES I RS MONI TR>
FMCS BI TE <FI XED1/OU
1TPUTS
<I NFLT FAULT <I NDEX
<CDU TEST BRT
<SENSORS INIT PERFRTEFACTR > CRZ DES
CLB
REF
<DI SCRETES I RS MONI TR >
DEP EXEC
MENU
<FI XED OUTPU TS LEGS ARR HOLD PROG
<I NDEX N1
LIMIT FIX
A B C D E
C
PREV NEXT M
A PAGE PAGE BRT
F G H I J S
L
INIT G
REF RTE LCLB
W CRZ DES
W
MENU LEGS DEP 1 2

HOLD
3
PROG
K
EXEC L M N O
FARR
N1 A 4 5 6 P Q R S T
LIMIT FIX I
L A A B C D E
C PREV NEXT W
A 7 8 9 U V M W X Y
PAGE PAGE S
L F G H I J
G
L W . 0 +/− Z SPW DEL / CLR
1 2 3 K L M N O
FMC (BITE-Part)
F
A 4 5 6 P Q R S T
I
L A
W
7 8 9 U V W X Y
. 0 +/− Z SP DEL / CLR
FMCS CDUs
FMS Subsystems
( digital )
DAAs
TEST RESET
EFIS SYMBOL
TEST GENERATOR RESET
EFIS SYMBOL
GENERATOR
Flight Control Computers A/T Computer FMC (Flight Management-Part) IRUs Symbol Generators
Other A/C Systems

( digital and analog )
Sys. 1 Sys. 2 Sys. 3 Sys. 4 Sys. 5 Sys. 6 Sys. X
...
LTT
Figure 8 Troubleshooting - FMS General

SAFETY ITEMS
General Example for a WARNING
During some maintenance tasks there is danger for personell or equipment When you remove a strobe position light you must not touch it after it is
when it is not done properly. switched off until five minutes are passed.
If there is danger for personell, a WARNING is shown in the task. For this reason, a warning is given in the related task.
If there is danger for eqipment, a CAUTION is shown in the task.
WARNING: DO NOT TOUCH THE LIGHT WITH YOUR BARE HANDS
UNTIL THE LIGHT IS OFF FOR A MINIMUM OF FIVE MIN-
Interfaces
UTES.
Sometimes a task includes an other task. DURING THIS TIME, YOU CAN RECEIVE AN INJURY IF
For example when you do a test of the auto pilot, hydraulic power may be YOU TOUCH THE LIGHT.
necessary. THE LIGHT CAN BURN YOUR SKIN OR GIVE YOU AN
Then there is a reference for the task how to pressurize the hydraulic power ELECTRICAL SHOCK.
system.
The warnings for hydraulic power will be shown in that task.
Example for a CAUTION

AC Generator Drive Oil System Leak Check (AMM 24−11−00)
CAUTION: DO NOT PUT MORE THAN 50 PSIG INTO THE GENERA-
TOR DRIVE SYSTEM. TOO MUCH PRESSURE CAN CAUSE
DAMAGE TO THE GENERATOR DRIVE SYSTEM.
A example for a task with a WARNING is shown in the figure below.

FRA US/E-1 WeR 2.3.05 Page: 18

WARNING
AMM 33−45−11
Figure 9 Safety Item

TOOLS
Special Tools and Equipment
A paragraph is provided in each maintenance task to summarize all Boeing,
supplier, and APU / engine manufacturer tools and test equipment specifically
designed to support the task.
All entries in this heading are identified with a part number and source.
Standard Tools and Equipment

Tools in this manual identified with an ”ST” prefix are designed by the Boeing
Commercial Company.
Detail drawings of these tools are available upon request.
The tools and equipment not normally found in a mechanic’s tool box are listed
in this paragraph.
Examples are:
Bonding meter
Clean, lint−free cloth
Container, 1 Gallon, suitable for collecting fuel
Plywood Sheet, 48 x 24 x 1/2 in. approximately.

737−3/4/5
Maintenance Manual
TASK 32−11−00−404−096
3.
Main Landing Gear Installation
A. Special Tools and Equipment
(1) Socket Wrench,Main Landing Gear Trunnion Link − ST2580−202. Use to tighten the bolt of the main landing gear forward
trunnion bearing to the applicable torque.
(2) Spanner Wrench, Main Landing Gear Forward Trunnion Bearing − 7ME65−73761−1. Use to install the main landing gear forward
trunnion bearing and bearing nut in the wing rear spar.
(3) Spanner Wrench, Main Landing Gear Trunnion Bearing − F80018−1. Use on 737−300/−500 airplanes to install the main landing
gear forward trunnion bearing and bearing nut in the wing rear spar.
(4) Spanner Wrench, Main Landing Gear Trunnion Bearing − F80018−2. Use on 737−400 airplanes to install the main landing gear
forward trunnion bearing and bearing nut in the wing rear spar.
(5) Adapter Wrench, Main Gear Trunnion Nut − F80020−5. Use to install nut for the trunnion link pin.
(6) Thread Protector and Alignment Tool, Main Landing Gear − F80115−1. Use on 737−300/−500 airplanes to protect the threads on the
trunnion link pin and to make the assembly of the trunnion link, trunnion link pin, shock strut and actuator beam arm easier.
(7) Thread Protector and Alignment Tool, Spring SupportShaft − F80115−2. Use to protect the threads of the spring support shaft.
(8) Thread Protector and Alignment Tool, Main Landing Gear − F80115−8. Use on 737−400 airplanes to protect the threads on the
trunnion link pin and to make the assembly of the trunnion link, trunnion link pin, shock strut and actuator beam arm easier.
(9) Thread Protector and Pin Alignment Tool, Main Landing Gear − F80141− 1. Use on the end of the shock strut aft trunnion journal
to make entry into the aft trunnion bearing easier.
(10) Spring Expander Set, Main Landing Gear − F80169−1. Use to remove the Main Landing Gear Downlock Springs. (OPTIONAL
TOOL).
(11) Torque Wrench Adapter − F80176−8. Use to torque the aft trunnion bearing nut.
B.
Standard Tools and Equipment
(1) Length of rope or cord used to extend the downlock springs during installation of main landing gear. (See Special Tools and
Equipment list for optional tool).
(2) Lead hammer
Figure 10 Special Tools

DOCUMENTATION B737
MAINTENANCE TIPS
MAINTENANCE TIPS
GENERAL
Purpose Applicability
The maintenance tip gives information that helps the mechanic in a procedure. The applicability gives Line numbers, airplanes, or part numbers and software if
The information is short and simple so it is easy to understand. It is published necessary.
and mailed within 10 days by Boeing Service Engineering. The maintenance tip
gives mechanics information to make repairs quickly and easily.
Condition
It has these sections:
The condition section gives a brief description of the condition.
Number
Release date
Subject Recommended Action
Applicability This section gives the actions necessary to dispatch the airplane. This section
Condition may include a sketch if applicable.
Recommended Action
Background (optional) Background (optional)
Maintenance Manual Action The background section gives the probable cause of the condition.
Reason For Cancellation (optional) It may tell how to prevent the condition.
Reference Message Number (#) (optional).
Maintenance Manual Action
Number This section shows which manuals have updates.
The maintenance tip number has five digits.
The first two digits are the ATA chapter. The Last three digits are the sequence
Reason For Cancellation (optional)
number for the ATA.
This section shows why this maintenance tip is no longer in effect.

CANCELLED also shows across the first page of the maintenance tip.
Release Date
This is the publication date for the maintenance tip.
Reference Message Number (#) (optional)
This section has the central maintenance computing system maintenance mes-
Subject sages shown in this tip.
The subject shows the topic of the procedure.

DOCUMENTATION B737
MAINTENANCE TIPS
Figure 11 Maintenance Tips

DOCUMENTATION B737/300/400/500
SYSTEM SCHEMATICS MANUAL

GENERAL
Purpose General Chapter
The System Schematics Manual (SSM) gives the user an understanding of There is a general chapter. It has chapter number 00.
system operation and helps in the fault isolation process. The general chapter has this customized data:
To do this, the manual includes this kind of information on the schematics: 00−00−00; Symbols
Component Locations 00−06−21; Airplane station Body and Stabilizer
Component identification (drawings) 00−06−30; Major Equipment Centers
Controls 00−12−00; Ground Service Access Panels.
Displays
Logic for system/subsystem operation.
NOTE:
Schematics and wiring diagrams show two important improvements that affect
Organization the maintenance technician.
The system schematics manual organization is by ATA chapter, then chapter/ First, the equipment number of an LRU on the 777 has the ATA chapter of the
section (subsystem). LRU as the first two numbers.
Each ATA chapter/section usually defines an airplane system or subsystem. These numbers are after the Letter that shows the kind of LRU (M, K, L, etc.).
Within an ATA chapter, the schematics show in increasing depth or complexity. Second, the connector numbers for an LRU are the same as the equipment
The schematic numbers follow this order: numbers with the letter ”D” in front.
ATA chapter/section (four-digit number) For example, the connector for the M33075 entry light is DM33075.
Schematic number (two-digit number) The exception to this is for connectors on power panels which have numerous
connectors.
Page number
In this case, the connector number has the panel number and a two-digit con-
Sheet number.
nector number.
For example, a connector on the P320 panel is D32012.

Page Numbers
Page numbers (Page 101, 102, etc.) show configurations of a schematic for
different airplanes in a customer’s fleet.
Sheet Numbers
There is a sheet number only if the schematic cannot show on one sheet.

DOCUMENTATION B737/300/400/500
Figure 12 System Schematics Manual (SSM)

INTRODUCTION
General Example
The introduction part of the SSM gives some information about the structure of The figure below shows a simplified schematic (level 2 schematic) for the left
the SSM and some details. Hydraulic System.
Three levels of schematics may be drawn to represent the system functions.
Effectivity
Block Diagrams The airplane effectivity code, Customer or Boeing assigned, of each schematic
Provides a broad overview of the system, or part of a system, showing major is noted in a box in the lower left corner of the schematic.
functions and components, functional groupings and pertinent interfaces. All sheets of a multiple−sheet schematic must have the same effectivity.
Simplified Schematics Pages

Provides a simplified view of the functions, components and interfaces. The Page numbers (Page 101, 102, etc.) are used to represent different deliv-
Broader in scope, showing more detail than level 1 schematics. Functions are ered configurations of a given schematic which maybe applicable to different
shown without regard to their location in the aircraft or to pin−to−pin circuits. airplanes within the customer’s fleet.
When a schematic page number has a suffix (e.g.,101A, 102A or 101.1, 102.1,
etc.) it reflects post delivery configuration for the same airplane(s) which may
Schematic result from the incorporation of service bulletins or other modifications.
A schematic shows the system in sufficient depth for fault isolation to the LRU
level.
Provides a detailed view of the functions, components, pin−to−pin connectivity
and interfaces.
Provides a link between the function and the physical implementation.
Provides the location reference for the components in the airplane.

HYDRAULICS HYDRAULICS MAIN GEAR

SYSTEM B SYSTEM A SELECTOR VALVE
2 3 PNEUMATIC 29−00−02 29−00−01 32−30−01
01 4 PRESSURE
PRESS GAGE
PSI X 1000 LWW INBD
V122 AUTOBRAKE
VALVE MDL
ACCUMULATOR ALTN SOURCE

RWW INBD SELECTOR VALVE
(STA 1235
LBL 30
WL 140)
CHARGING ACCUMULATOR
VALVE ISOLATION VALVE S811 ALTN BRAKE
RTN BRAKE PRESS SELECT VALVE
PRESS SW
(STA 700)
V7 L INBD ANTISKID VALVE L PEDAL
PRESSURE R PEDAL
(SAME AS V8,V9,V10,V124 AND V125) PRESSURE
LGB−A1
R NORMAL BRAKE LGB−A2
LGB−B1 METERING VALVE
LGB−B2
L NORMAL BRAKE
METERING VALVE
FOR
DETAILS
BRAKE FEEL SEE
BRAKE FEEL ACTUATOR VIEW 2
ACTUATOR
R AUTO TO ANTISKID/
L AUTO BRAKE AUTOBRAKE
TO ANTISKID/ BRAKE SHUTTLE >750 PSI CONTROL UNIT
AUTOBRAKE >750 PSI SHUTTLE VALVE
LGB−A1 VALVE
LGB−A2 CONTROL UNIT LGB−B1
S762 L MET PRESS SW S763 R MET PRESS SW LGB−B2
VIEW 2 L PEDAL R PEDAL
LEFT BRAKE METERING PRESSURE PRESSURE
VALVE INSTALLATION
(RIGHT BRAKE METERING
VALVE SIMILAR) V11 RIGHT ALTN
PARKING BRAKE
BRAKE METERING
HYD LEFT ALTN VALVE
PORT BRAKE VALVE
METERING
FILL VALVE
VALVE
ANTI−SKID
TRANSDUCER
V125 LEFT
ALTN SYS
ANTISKID
THERMAL VALVE
FUSE
PLUG
NORMAL SYS V124 RIGHT ALTN
ANTISKID VALVES SYSTEM ANTISKID
VALVE
V9 L OUTBD V7 L INBD V8 R INBD V10 R OUTBD
ANTISKID
Effectivity VIEW 1
BRAKE WEAR INDICATOR
VIEW 1
BRAKE WEAR INDICATOR
SHUTTLE VALVES
(SHEET 1)SHEET 1)
METERED PRESSURE
SYSTEM PRESSURE
NITROGEN LEFT MAIN BRAKES RIGHT MAIN BRAKES
FWD
SYSTEM RETURN
Page
PQ051−PQ085 BRAKE SYSTEM − SIMPLIFIED 32−40−00
PAGE 101
AUG 29/1997
Figure 13 Simplified Schematic

SCHEMATIC
Presentation Equipment Numbers
The schematics show each system in a functionally integrated presentation Equipment numbers (reference designators) are assigned to each airplane
that: component with wiring attached, all Line Replaceable Units (LRU), panels and
Identifies and locates all LRU’s and shows their functional internal circuitry racks.
in a simplified manner. Not all components with equipment numbers are LRUs and not all LRU’s are
Identifies connections between LRU’s with cross reference to all interfacing assigned an equipment number.
system schematics. The equipment number uniquely identifies a component. However, if a compo-
Provides signal flow for primary functions which require airplane wiring or nent is part of an assembly, the equipment number will be the same for each
observable indications. use of the assembly in the airplane.
The equipment nomenclature used in the SSM and WDM consists of the com-
Layout ponent name, followed by a location modifier (e.g., VHF Radio−Left).
The preferred schematic layout is power on the left and load on the right; signal
source on the left, and signal destination/indication on the right.
After satisfying proper left to right flow, the equipment is shown in relation to its LRUs
position in the airplane, when possible. The schematic identifies which equipment is a Line Replaceable Unit (LRU) by
Left is forward, right is aft, top is right, bottom is left. the width of the box representing the equipment.
Equipment that is not an LRU is identified with a solid thin line. The LRU is
identified with the solid wide line if it is shown in the home ATA system.
Configuration It is identified by a wide cross−hatched line if the circuit functions are duplicated
Unless otherwise noted, all schematics are shown with the airplane on the in another interfacing ATA system.
ground, after a normal flight, and with the post−flight checklist completed Provisional equipment not installed on an airplane at the time of delivery is
(power off). identified by dash equipment boxes; however, the wiring has been installed to
Instruments, indicators and monitors may reflect other conditions where clarity allow installation of the equipment at a later date.
of presentation is improved. The schematic which shows the primary function of the LRU is the home for
that LRU.
If the LRU is not shown in its entirety on its home schematic, a continuation
Sheets
break (Z−break) is used to indicate that the LRU is shown incomplete.

Complex subsystems may require more than one schematic sheet. In general,
In this case, a reference to the ”home schematic” is placed in the top center of
the subsystem shows the related functions on one schematic.
the LRU box.
Multiple schematics may also be used to show the function of the subsystem.
LRUs with multiple primary functions shown in multiple systems are identified
”SCHEM” numbers may also be assigned to schematics depicting subfunctions
with Z−breaks. References are not included on the home schematic.
of primary function.
Additionally, each schematic may require multiple sheets. Odd−numbered
sheets are printed on the left side of the binding and even−numbered sheets on
the right. This allows the schematic to be read across the binding edge.

WIRING DIAGRAMS
33−43−01
32−31−11
4 GND
5 D2796
6 8 D2796 D144
9 A 115V AC IN
AIR
B GND
ON
AUTO
OFF R320 AIR/GRN L44 RIGHT WINGTIP
115V AC 1 RELAY (E11 SHELF) STROBE LIGHT
TRANSFER (WCP 0 WBL 560)
BUS 1 öC
24−51−11 5 2
C115
POSITION − D146
STROBE (B14) A 115V AC IN
=P G =G
B GND
S636 STROBE LIGHTS (P5)
L38 RIGHT L45 RIGHT WINGTIP
POSITION LIGHT STROBE LIGHT
(WCP 0 WBL 565) (WCP 0 WBL 560)
D148
=P G =G B 115V AC IN
D GND
L39 RIGHT
POSITION LIGHT L46 TAIL STROBE LT
(WCP 0 WBL 565) (STA 1216 WL 284 BL 0)
28V AC
TRANSFER
BUS 2
24−53−11 10 1
C113 2 =P W =G
POSITION − 3
STEADY (B15)
L42 RIGHT TAIL
ON POSITION LIGHT
OFF (WCP 0 WBL 565)
ON BATTERY
(GND ONLY)
28V DC
BATTERY 4
BUS 5 =P W =G
24−61−11 10 6 LEFT WING
C114 STROBE LIGHT
POSITION −
BATTERY (B16) S58 POSITION LIGHTS (P5) L43 LEFT TAIL
POSITION LIGHT LEFT POSITION
(WCP 0 WBL 565) LIGHT − RED
P18−3 PASSENGER CABIN AND EXTERIOR
LIGHTING, WINDOW HEAT AND ANTI−ICE
LEFT TAIL
POSITION LIGHT
=P R =G
L40 LEFT
POSITION LIGHT TAIL STROBE LIGHT

(WCP 0 WBL 565) RIGHT WING RIGHT TAIL
STROBE LIGHT POSITION LIGHT
RIGHT POSITION
LIGHT − GREEN
=P R =G
L41 LEFT
POSITION LIGHT
(WCP 0 WBL 565)
ALL EXTERIOR LIGHTS −

33−43−11
Page 101
Figure 14 Schematic
REGISTRATION CROSS REFERENCE

General
The variable number is assigned to an airplane from a block reserved for a
specific customer.
The number is used to identify airplanes for engineering basic design and
change effectivities on drawings, documentation and correspondence.
Customer Code
The customer code number is assigned by the customer and is usually based
on the registration number.
Registration Number
The registration number or tail number is assigned by the responsible govern-
ment aviation authority.
The manufacturing serial number and registration number are unique for each
airplane.
MSN
The manufacturing serial number appears on the airworthiness certificate and
on the airplane’s name plate, which is located in the upper door sill of the right
forward door.
Line Number
The line number reflects the manufacturing rollout sequence for each model.

Figure 15 Registration Cross Reference

WIRING DIAGRAM MANUAL

GENERAL
Purpose Modification Incorporation Index
The Wiring Diagram Manual (WDM) gives details of the point to-point wiring on The modification incorporation index of the WDM has the same structure as the
the airplane. index in the SSM.
It shows all connectors including breakout and shelf connectors.
The wiring diagram shows simple internal components of LRUs so the user
Registration Cross Reference
may better understand the signal flow and purpose of the wiring.
The registration cross reference has the same structure as the reference in the
Internal components do not show if they are complex or if the signal(s) comes
SSM.
from or goes to software.
Organization
The organization of the wiring diagram manual is similar to the system sche-
matic manual.
It uses the ATA chapter/section organization.
These are the sections of the wiring diagram manual:
Equipment List
Diagrams
Charts
Hook up list
Wire List
Circuit breaker list
Disconnect bracket list.

− 300
− 400
− 500
Figure 16 Wiring Diagram Manual

DOCUMENTATION BOEING
LISTS
General Circuit Breaker List
The WDM has various lists which are regarded as part of WDM chapter 91. In the WDM, the Circuit Breaker List has the Sub-Section 91−02.
The Circuit Breaker List is derived from data contained in the Equipment List.
It lists, in alphanumeric order, each panel that contains circuit breakers and the
Lists
circuit breaker grid location for each panel.
The lists are as follows:
For each used grid location (GRID NO.), the circuit breaker number (CKT
Circuit Breaker List BKR), title (DESCRIPTION), DIAGRAM and EFFECTIVITY are listed.
Bracket List Unused grid locations are not listed.
Wire List The Circuit Breaker List is used as supplemental data for all Chapter
Ground List 91−02−XX Location Charts containing circuit breakers.
Splice List
Terminal Strip List
Hookup List.
Fra US/E-1 WeR 5.3.05 Page: 34

PANEL NO
REV GRID NO CKT BKR DESCRIPTION DIAGRAM EFFECTIVITY
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
P034−00
B27 C21451 CB−R DR 4 HTR 21−45−26 ALL
C09 C21452 CB−R SATCOM BACKUP CLG FAN 21−26−52 ALL
F07 C21600 CB−EQPT CLG SPLY FAN 2 CTRL 21−27−32 ALL
G01 C21608 CB−R LAV/GLY FAN CTRL 21−26−11 ALL
P06 C21610 CB−R FWD OFL VLV 21−32−11 ALL
P07 C21612 CB−R AFT OFL VLV 21−32−11 ALL
G02 C21616 CB−BULK CGO HT SOV 21−44−21 ALL
Figure 17 Circuit Breaker List

Wire List
The Wire List reflects the wire bundles on the aircraft in alphanumeric order LENGTH FT/IN Field (Wire Length)
and the wires within each bundle. − The length of the wire is shown in this field. Critical lengths and toler-
REV Field (Revision) ances will be shown on diagrams for applicable wires or bundles.
The revision field is blank unless an entry has been changed. The codes − A wire without a length will appear if it is part of a family of wires.
used in this field are ’A’ for add, ’R’ for revised, or ’D’ for deleted. The length for this particular wire is usually specified on the lowest wire
number in that family group.
MOD Field (Modification)
The modification field is not used. DIAGRAM Field (Diagram Reference)
The numbers in this field reflect the diagram on which the wire appears.
WIRE BUNDLE PART NUMBER AND TITLE Field The diagram references apply to any functional or spare wire.
The wire bundle part number is derived from the wire bundle drawing num- Spare wires may be found in the Wire List, Ground List, Terminal Strip List,
ber. A title or description of the bundle follows the part number. Splice List and Hookup List with ”SP−AR−E” in the DIAGRAM field.
BUNDLE Field (Wire Bundle Number) EQUIP Field (Equipment Number)

Each wire bundle is given an item number beginning with ”W”. There are two EQUIP fields, one for each end of the wire.
This item number is the first part of the wire number and is derived from the Any item designator found in this field, other than splices and grounds, will
wire bundle drawing number. be defined in the Equipment List.
The four digits XXXX of the item number is the wire bundle number. The
first part of the wire number thus becomes WXXXX. TERM Field (Terminal Number)
Wire bundle numbers W9001−W9999 are reserved for customer use. There are two TERM fields, one for each end of the wire.
The contact identifiers in these fields are typically alphanumeric characters.
WIRE/GA/CO Field (Wire Number/Guage/Color) The codes are explained in the Wire List part of the introduction.
A typical wire number consists of the wire identifier and gauge.
A color designator may appear at the end of the wire identifier or gauge TT Field (Terminal Type)
number. The Terminal Type codes appearing in this field are defined in the CODES
Wire numbers 901−999 and 9001−9999 are reserved for cusotmer use. section identifying:
− Codes for Lug (Stud) size (diagram symbol depicted).
TY Field (Wire Type)

− Codes for Special Terminals.
The Wire Type code is a two−character identifier for the type of wire used.
These codes are described in 20−00−13 of the Standard Wiring Practices. − Codes for Special Contacts.
FA Field (Wire Family) SP Field (Splice)

Multi−conductor wires such as twisted or shielded wires are grouped as a This field shows conditions under which the connection is made. The codes
family of wires. are explained in the Wire List part of the introduction.
Each family of wires is given a code which is unique per bundle.
EFFECTIVITY Field
Sows the airplane effectivity.

R M BUNDLE PART NUMBER AND TITLE

E O −−−−−−−−−−−−−−−−−−−−−− LENGTH
V D BUNDLE /WIRE /GA /CO TY FA FT /IN DIAGRAM EQUIP TERM TT SP EQUIP TERM TT SP EFFECTIVITY
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
E6−2 SHELF WIRE ASSEMBLIES − RR2
W2626 −0030 −22 PA 3 00 32−42−15 DM32017AB E09 D07356P 21 ALL
−0031 −22 PA 3 00 32−42−15 DM32017AB E11 D07356P 22 ALL
−0101 −22 PA 3 00 32−42−14 DM32017AA D05 GB46018 D.. 1A ALL
−1001 −22 RO AA 3 00 32−42−14 DM32017AA G07 D07356P 1 ALL
−1001Z AA 32−42−14 DM32017AA DED D07356P DED ALL
−1002 −22 RO AB 3 00 32−42−14 DM32017AA J07 D07356P 2 ALL
−1002Z AB 32−42−14 DM32017AA DED D07356P DED ALL
Figure 18 Wire List

EQUIPMENT LIST
General When more than one option is available, the four allowed options are:
Electrical and electronic equipment are shown on wiring diagrams and sche- OPT Option available
matics with alphanumeric designators. 9 First Option
These designators are used as cross−reference symbols to the Equipment List 8 Second Option
where the Part Numbers and Part Descriptions are shown. 7 Third Option
Splices, grounds, terminals and wire bundles are not included in the Equipment 6 Fourth Option
List. PART NUMBER Field
The Part Number field provides the part number for the equipment item. It
will be a unique number defined by either vendor, Military or Boeing drawing
Equipment List Data Fields and/or specification.
The data fiels are as follows: PART DESCRIPTION Field
REV Field (Revision) The Part Description is derived from the actual use of the item or the title of
The Revision Field is blank unless an entry has been changed. The codes its associated drawing or specification.
used in this field are ”A” for add, ”R” for revised, ”D” for deleted. USED ON DWG Field (Used−on Drawing)
MOD Field (Modification) The Drawing that contains installation details for that part.
The Modification field is not used. CH 20 REF Field (Chapter 20 Reference)
EQUIP Field (Equipment Number) This column is used for connector items and contains the Chapter−Section−
The Equipment Number field may contain up to ten alphanumeric charac- Subject number reference to the Standard Wiring Practices (Chapter 20).
ters. The Equipment Number always begins with a letter and may contain a VENDOR Field (Vendor Code)
space followed by another character. − For Vendor Code translation, refer to:
OPT Field (Option) H4−1: Federal Supply Code for Manufacturers−Name to Code
The Option field indicates if optional part numbers may be used, and if so,
H4−2: Federal Supply Code for Manufacturers−Code to Name
the order of preference.
QTY Field (Quantity)
− Boeing ”as delivered” Options:
The Quantity shown reflects the number of times each item is used on the
When the OPT field is empty or a zero appears, no options are permitted
airplane.
due to systems or physical restrictions. A ”1” indicates that options are
available. DIAGRAM Field

0 No Option The Diagram listed is the diagram or schematic on which the item appears.
1 First Option However, one item maybe shown on more than one diagram or schematic.
2 Second Option STATION −WL −BL Field (Location)
3 Third Option If the equipment is located on or near a panel, equipment rack, disconnect
− Customer Requested Options: panel or terminal block, that item is referenced for locations. All other equip-
Customer requested options are used for the incorporation of post−deliv- ment locations are shown by station line, water line, and buttock line.
ery changes, such as Boeing Service Bulletins and Customer Originated
Changes. Option ”9” is used for the incorporation of these changes.

Figure 19 Equipment List

WDM USAGE
How To Locate A Diagram From A Wire Found In The Airplane
This is the example with wire number W346−004−22.
Knowing the wire bundle number W346, refer to the Wire List in Chapter 91.
1. Using self indexing wire list shown, locate wire bundle W346.
2. Locate wire number 004−22 and on the same line under the ”Diagram”
heading locate the diagram number 35−21−11.
Sheet 1 Effectivity: ALL
3. Refer to Chapter 35 and locate the information needed on diagram
35−21−11.

DISC.
STA 259L
C156 W018 W330−
28V DC 1 W084 W346−
2 048−22 9 005−22 5 1
004−22 P
BAT. BUS 5
35−21−21 P 544−22 8
J D4040P D4606J W346−
24−56−01
OXYGEN GD1008−DC 104−22 2
INDICATOR
W346−
3
P18−3 005−22
P18 LOAD CONTROL CENTER − LEFT

PASSENGER CABIN AND EXTERIOR LIGHTING,
WINDOW HEAT AND ANTI−ICE D438 T404
TRANSMITTER
DISC. CREW OXYGEN
STA 270R
W038 STA 400 RBL 50 WL 180
W230−
022−22 543−22 W346−
1 14 031−22 31 SM 4
11 014−22
P D4058J P
071−22 1 102−16 D4534J
2
3 T232 GD934−DC P D4556J
4 33−12−01
E3−2 ELECTRICAL SHELF W346−
D432 006−22 1
N20 GD1008−DC W346− 2
P5−14 CREW OXYGEN 105−22
OXYGEN SYSTEM D434 N21
MODULE
PRESSURE INDICATOR P24 STA 390R
CREW OXYGEN
PRESS. IND
P5 OVERHEAD PANEL − AFT EXTERNAL CHARGING PANEL
CREW OXYGEN SYSTEM 35−21−11

PQ051−PQ085 PQ088−PQ092 PS701−PS706 PAGE 1
OCT 18/2004
Figure 20 Wiring Diagram 35−21−11

IPC
ILLUSTRATED PARTS CATALOG

GENERAL
Structure of the IPC SUPPLIER CODE − The digit code which identifies the manufacturer of the
The IPC has the following structure: part. The Supplier Code is found in the nomenclature column following the sup-
plier part number entry.
Introduction
Explanation of Illustration Technique (see text below)
SPECIFICATION NUMBER and QUALIFIED PARTS − The Specification Num-
Airplane Effectivity Cross Reference Index
ber is a Boeing assigned number which defines all of the necessary part perfor-
Airplane Sectional/Station Diagrams mance requirements a supplier must comply with to be qualified to produce the
Major Zone/Index Diagrams part. The Boeing Specification number is documented in the Part Number col-
Filter Maintenance Kit List umn when no supplier part has been qualified. When a supplier part qualifies to
a Boeing Specification, the supplier part number is shown in the Part Number
Suppliers Name and Address List
column and the specification is placed in the Nomenclature column. Any addi-
Service Bulletin And Modification List tional qualified supplier parts are captured as optional parts in the nomencla-
Major Drawing Number Index ture column.
Chapters
USED ON − A note in the Nomenclature column which indicates the appropri-
ate next higher assembly when the part is not common to all of the next higher
Explanation of Parts List Data assemblies listed preceding the part.
The following is an explanation of the data provided on parts lists included
within the Illustrated Parts Catalog.
ALTERED FROM − An existing component that was altered to create another
part number. There are only minor modification differences between the original
NEXT HIGHER ASSEMBLY (NHA) CROSS REFERENCE − The reference (Altered from) part number and the new part number.
catalog location indicates where the used on component or assembly is de- Where a design change produces a qualified or limited interchangeability condi-
fined. tion, the delivered effectivity is shown and an appropriate note is included in the
UNITS PER ASSEMBLY (UPA)− The quantity of the part which is used on the nomenclature column to define this condition. The relationship between parts
NHA assembly. The following entries other than a numeric value maybe found shown in interchangeability notes is defined by the following terms:
in the IPC data: REPLACES OR REPL BY − Indicates the parts (or sets) are physically and
”RF” (Reference) − Indicates the item is listed at the NHA location which functionally interchangeable.
carries the UPA quantity. The NHA location is found through the NHA cross MAY USE − Indicates a one−way interchangeability exists, either forward or
reference. backward, depending on the parts involved.
“AR” (As Required) − Indicates the part is used in a quantity determined at T/W (together with) − Indicates parts which are necessary to be replaced
the time when the part is installed. along with the main part for interchangeability. Interchangeability is only ac-
complished as specified by the note.

IPC
Figure 21 Illustrated Parts Catalog

IPC
OVERLENGTH PART NUMBER − A Boeing Company Reference(BCREF) FIGURE TITLE − Where more than one lead entry or subject is included in a
number is assigned to all overlength part numbers which exceed 15 digits. The figure, a figure title is used to facilitate the preparation and maintenance of the
BCREF number is placed in the Part column and the overlength number is in Chapter Table of Contents entries. The Effectivity column for the figure title
the nomenclature column. identifies the aircraft covered in the figure.
TEMPORARY BREAKDOWN − A note which is included in the IPC when a SERVICE BULLETIN ENTRIES − Boeing Service Bulletins are incorporated in
design change produces an assembly part number for which breakdown infor- the IPC only upon notification from the airline that the intent of the SB has been
mation is not available. Breakdown components for the current assembly are accomplished.
extended as a applicable for the new assembly.
FILTER MAINTENANCE KITS − Boeing defines a kit part number which con-
BOEING STANDARD PARTS − Boeing Standard Parts are identified by a BAC tains all of the parts necessary to support the removal and maintenance of a
prefix. The Boeing Standard Part Number appears in the part number column filter on the airplane. The kit is a convenience to the operator and contains the
when no supplier part has yet been qualified. filter/module element(s), packing(s)/O−ring(s), gaskets and all standard parts
necessary for maintaining the element. The filter Maintenance Kit part number
is referenced in the nomenclature column of the element entry. The definition of
CHANGE INDICATORS − Change indicators are applied opposite the revised
the Filter Maintenance Kit contents are detailed in the Filter Maintenance Kit
data line entry. An ”R” in the margin indicates the line opposite was added or
section of the IPC.
revised in the current revision.
When the Parts List page for a figure includes Airline Stock Numbers, the letter
”S” is shown opposite the line entry When a change in the Airline Stock Num- ELECTRICAL EQUIPMENT NUMBER − The Wiring Diagram equipment num-
ber data is the only Change to the item entry. bers are referenced in the IPC nomenclature as applicable to a documented
BOEING PROPRIETARY COLOR CODED PARTS − Boeing Proprietary Color part. Electrical Equipment Numbers also appear in the IPC on placards for
Coded Parts, excluding Boeing specification part numbers 10−XXXXX, identifying equipment.
SXXXNXXX, SXXXTXXX, SXXXUXXX, SXXXWXXX or 60BXXXXX, are identi-
fied with an alpha ”SP” suffix. This entry represents consolidation of all color ETOPS ENTRIES − The IPC defines parts which are required to support Ex-
codes applicable for the given usage. Color coded parts may be ordered with tended Twin Operation (ETOPS) for two engine aircraft. ETOPS notes appear
either the specific airline (alpha) color code suffix or the consolidated ”SP” suf- in the nomenclature field of the IPC under the following conditions:
fix. Orders received for ”SP” parts will be converted and processed under the ”Not Approved for ETOPS” Means that part can not be installed to meet
airlines (alpha) color coded part number. A reference to the appropriate aircraft ETOPS flying requirements.
registry number or the color name on orders for ”SP” parts will facilitate the ”Not Approved For ETOPS After Service Bulletin or Service Letter Incorpora-
color conversion. tion” Means that the part is not certified for ETOPS if the referenced Service
Note: Color code does not affect physical or functional interchangeability as- Bulletin or Service Letter is incorporated on the airplane.
pects.
MAINTENANCE MANUAL REFERENCE − A cross reference to the applicable
LOCAL FABRICATION PARTS − Material requirements for parts which can be Boeing Maintenance Manual location which contains the procedure for removal
locally fabricated are included in the Nomen− clature column within a (MFD and repair of that part.
FROM−−) note.

IPC
Figure 22 Illustrated Parts Catalog

IPC
ILLUSTRATION
General
The illustration portion of a figure in the Illustrated Parts Catalog pictorially dis-
plays the relationship of the parts identified in the Parts List.
The following is an explanation of certain techniques used in the illustration to
present the relationship of these parts.
The numbers correspond to those shown in the following sample:
1. Detail coverage of any portion of the illustration is provided by isolating sec-
tions in specific exploded views with alphabetic designations.
2. Components of assemblies are shown either within a specific exploded view
of the assembly or the item numbers of the components are included within a
bracket which is identified by the item number of the assembly.
3. When a component is physically illustrated such that a lead line from the
item number within a bracket to the illus− tration of the part would be confusing
or indeterminate, an arrow is used to point in the direction of the illustrated
component.

IPC
1
IPC Explanation of Illustration Technique
Figure 23 IPC Illustration

DOCUMENTATION B737
DDPG
DISPATCH DEVIATIONS PROCEDURES GUIDE

GENERAL
Purpose Procedures
This document is intended to assist airline operations and maintenance organi- Items for which the FAA feels special procedures are necessary are identified
zations in developing the procedures required to operate the aircraft in the vari- in the MMEL by an (M) and/or (O).
ous nonstandard configurations allowed by the Federal Aviation Administration (M) indicates that specific procedures must be accomplished to configure
(FAA) Master Minimum Equipment List (MMEL) and the Airplane Flight Manual the airplane for flight with the inoperative item.
(AFM) appendix Configuration Deviation List (CDL). These procedures may be accomplished by maintenance or other personnel
as determined by the airline.
(O) indicates normal flight crew procedures are modified or supplemented to
Basic Structure
account for the inoperative item.
The DDPG is divided into 5 sections:
Introduction
Master Minimm Equipment List Ferry Items
Configuration Deviation List Items Section 4 is provided for insertion of information for dispatch with selected con-
figuration deviations, for which revenue operation is not allowed by the MMEL
Ferry Items
or CDL, when it is necessary to fly the aircraft back to a maintenance base for
Miscellaneous Items. repairs.
When Boeing feels that such a configuration can be clearly defined, the
appropriate performance data and procedures will be included.
Introduction
The FAA publishes an MMEL for each airplane model that is written in very
brief format. Miscellaneous Items
Additional operator amplification is intended before use, since the MMEL does Up to now, section 5 is only about dispatch with damaged windows.
not always include the special procedures necessary to properly prepare and
Requirements for replacement of damaged windows are discussed in Chapter
operate the airplane.
56 of the Maintenance Manual.
The CDL is published as an Appendix to the FAA Approved AFM and includes Dispatch with window damage that does not required replacement per the
secondary airframe and engine parts which may be missing for dispatch. maintenance manual is permitted.
The CDL does not include illustrations for positive identification of those parts.
The FAA Air Carrier Inspector’s Handbook states that it is the operator’s re-
sponsibility to develop a company MEL with procedures using the Master MEL
as a guide and to obtain approval of their company MEL from the assigned
FAA Principal Operations Inspector to determine that:
adequate procedures have been developed
the company MEL is not less restrictive than the Master MEL .

DOCUMENTATION B737
DDPG
Figure 24 DDPG Section 1

DOCUMENTATION B737
DDPG
MASTER MINIMUM EQUIPMENT LIST (MMEL)

Purpose Example
Section 2 contains all items from the current MMEL (Master Minimum Equip- For the Pack Ram Air Systems, the item number is 21−5.
ment List).
Items are given in the same sequence that they appear in the MMEL.
For ease of use, page numbering uses the appropriate ATA Number assigned
to MMEL items.
Boeing suggested procedures follow the applicable item.
In the following cases an item WILL NOT befollowed by a suggested
procedure:
The procedure is obvious.
Boeing is not aware of any procedural effects.
The procedure must be supplied by the airline as it depends on operating
requirements.
The MMEL does not require that a procedure be established.
System Diagrams
At the beginning of some chapters there are system diagrams.
They show system components and the related MMEL item number.

DOCUMENTATION B737
DDPG
Figure 25 DDPG Section 2

DOCUMENTATION B737
DDPG
System Definitions Symbols

System numbers are based on the Air Transport Association (ATA) Specifica- ”(M)” symbol indicates a requirement for a specific maintenance procedure
tion Number 100 and items are numbered sequentially. which must be accomplished prior to operation with the listed item inoperative.
”Item” (Column 1) means the equipment, system, component, or function Normally these procedures are accomplished by maintenance personnel; how-
listed in the ”Item” column. ever, other personnel may be qualified and authorized to perform certain func-
”Number Installed” (Column 2) is the number (quantity) of items normally tions.
installed in the aircraft. This number represents the aircraft configuration Procedures requiring specialized knowledge or skill, or requiring the use of
considered in developing this MMEL. Should the number be a variable (e.g., tools or test equipment should be accomplished by maintenance personnel.
passenger cabin items) a number is not required. ”(O)” symbol indicates a requirement for a specific operations procedure which
”Number Required for Dispatch” (Column 3) is the minimum number (quan- must be accomplished in planning for and/or operating with the listed item inop-
tity) of items required for operation provided the conditions specified in Col- erative.
umn 4 are met. Normally these procedures are accomplished by the flight crew; however, other
NOTE: Where the MMEL shows a variable number required for dispatch, personnel may be qualified and authorized to perform certain functions.
the MEL must reflect the actual number required for dispatch or an alternate
means of configuration control approved by the administrator. Definitions
”Remarks or Exceptions” (Column 4) in this column includes a statement At the beginning of the MMEL, there are definitions for the following terms:
either prohibiting or permitting operation with a specific number of items in- Deactivated and Secured
operative, provisos (conditions and limitations) for such operation, and ap- Visual Flight Rules (VFR)
propriate notes.
Visual Meteorological Conditions (VMC)
Visible Moisture
Inoperative Items Passenger Convenience Items.
Each inoperative item must be placarded to inform and remind the crewmem-
bers and maintenance personnel of the equipment condition. REPAIR INTERVALS
NOTE: To the extent practical, placards should be located adjacent to the con- All users of an approved MEL must effect repairs of inoperative systems or
trol or indicator for the item affected; however, unless otherwise specified, plac- components at or prior to the repair times established by the following:
ard wording and location will be determined by the operator. Category A items shall be repaired within the time interval specified in the
remarks column of the operator’s approved MEL.
Category B items shall be repaired within three consecutive calendar days,

ER excluding the day the malfunction was recorded in the aircraft maintenance
”ER” refers to extended range operations of a two−engine airplane which has a record/logbook.
type design approval for ER operations. Category C items shall be repaired within ten consecutive calendar days,
excluding the day the malfunction was recorded in the aircraft maintenance
record/logbook.
Category D items shall be repaired within one hundred and twenty consec-
utive calendar days, excluding the day the malfunction was recorded in the
aircraft maintenance log and/or record.

DOCUMENTATION B737
DDPG
Figure 26 Item 21−5

DOCUMENTATION B737
DDPG
CONFIGURATION DEVIATION LISTS (CDL)

General Weight Reductions
Section 3 (Configuration Deviation List) contains illustrations of the various The performance penalties are cumulative unless specifically designed penal-
CDL items, plus information on system effects and enroute performance ef- ties for combination of missing parts are indicated.
fects, as appropriate. Where performance penalties are listed as negligible, no more than three negli-
The CDL includes secondary airframe and engine parts which may be missing gible items may be missing without taking further penalty.
for dispatch. For each missing item more than three, reduce the takeoff, landing and enroute
The CDL does not include illustrations for positive identification of those parts. climb limits by 100 pounds (46 kilograms).
Where performance penalties are listed as no penalty, any accumulative num-
ber of items listed as no penalty may be missing without further penalty.
Placard for Pilots
The associated limitations must be listed on a placard affixed in the cockpit in
clear view of the pilot−incommand and other appropriate crew member(s).
Operation with those missing parts requiring a reduction of VMO/MMO is per-
mitted only when the airplane has the appropriate alternate VMO set prior to
flight.
TLB Entry
The operator will list in the aircraft logbook an appropriate notation covering the
missing part(s) on each flight.
More parts lost next flight

If an additional part is lost in flight the airplane may not depart the airport at
which it landed following this event until it again complies with CDL limitations.
This, of course, does not preclude the issuance of a ferry permit to allow the
airplane to be flown to a point where the necessary repairs or replacements

can be made.
No more than one part for any one sub−system in the CDL may be missing
unless specifically designated combinations are indicated. Unless otherwise
specified, parts from different sub−systems may be missing.
The CDL does not provide information regarding dispatch with missing fasten-
ers.
Refer to Structural Repair Manual (SRM) Section 51−10−05 for conditions and
limitations which permit operations with fasteners missing.

DOCUMENTATION B737
DDPG
Figure 27 CDL Index

DOCUMENTATION B737
DDPG
Typical List
For each item there is an own page.
The items start with ATA 21.
On the figure below there is an example of ATA 33.
Table
For each item there is a table with five rows:
Number (see index)
Item (Name of the item)
Model (which series are affected)
Number of items installed

Illustration
For each item there is an illustration.

DOCUMENTATION B737
DDPG
Figure 28 CDL Example Chapter 33

DOCUMENTATION B737-300/400/500
SRM
STRUCTURAL REPAIR MANUAL

GENERAL
General Chapters
The Structural Repair Manual (SRM) has been prepared in accordance with Air The manual is divided into the following chapters:
Transport Association Specification Number 100 (ATA Spec. 100). Chapter 51 - Structures, General
Chapter 52 - Doors
RVSM Chapter 53 - Fuselage
Inspection/Check instructions for RVSM are given in AMM 51−10. Chapter 54 - Nacelles and Pylons
However, the tasks are linked with instructions and limits in the SRM. Chapter 55 - Stabilizers
Chapter 56 - Windows
Chapter 57 - Wings.
Coverage
The purpose of the SRM is to provide data on the field repair of primary and
secondary structure. Topics
Data in this manual which affects structural integrity is FAA approved prior to Each chapter is sub-divided further into sections and subjects. Section num-
application. bers indicate a sud-division of a major area (e.g. fuselage section 41, wing cen-
Where repairs are not included, it does not follow that the structure concerned ter section).
is not repairable. The subject numbers are allocated to the structural elements (e.g. skins, string-
Either it has not been found practicable to design a typical repair, or service ers, etc)
experience has not yet indicated a requirement.
Consider the following when typical repairs are not found: Chapter 52 - 57 contain three basic topics:
Accomplish a repair in accordance with the general repair practices and pro- Page Block 1 - 99 Structure Identification
cedures provided in chapter 51 of the SRM Page Block 101 - 199 Allowable Damage
Replace the part Page Block 201 - 999 Repairs
In some instances, an adequate repair design has to be prepared by engi-

neering and will require evaluation by the manufacturer.
FRA US/E-1 Sc/WeR 2.5.05 Page: 58

SRM
Figure 29 Standard Number System

FRA US/E-1 Sc/WeR 2.5.05 Page: 59
SRM
STRUCTURES - GENERAL
General Fasteners
SRM Chapter 51 (Structures - General) deals with those subjects which are Fastener Codes
general in nature to the entire structure of the airplane. Installation and Removal
It contains the following subjects: Substitution Data
Major Assembly Breakdown Torque Values
Principal Dimensions Hole Sizes
Structure Classification Edge Margins
Abbreviations Countersinking
Cold Working
Damage Removal Strength Values
Approved methods for damage clean-up.
Support of Airplane for Repair
Aerodynamic Smoothness Details of supports and loads which can be applied at various points on the
structure.
Requirements and recommendations for flight safety and economic reasons.
Alignment or Symmetry Checks:

Processes and Procedures
Means of checking for significant deformation of the structure.
General procedures such as protective treatment, hardness testing and fire
damage evaluation.
Composite Repair Instructions
Materials Detailed repair instructions for all composite fabric components including wet
lay-up repairs and hot bonding repairs to fibreglass, carbon fibre, aramid fibre
Sheet Metal
as well as hybrid fabric components and sandwich components.
Minimum Bend Radii

Extrusions and Formed Sections
Non-metallic Materials
Substitution Data
HAM US/F Sc 2.6.98 Page: 60

SRM
Figure 30 Manual Number System

SRM
MANUAL USAGE
The Structural Repair Manual is divided into three topics :
Identification
Allowable Damage
Repair
The relevant procedures to find the applicable topic will be described on the
following pages.

SRM
B B
C
A
Figure 31 How to Use the Manual

SRM
DAMAGE CLASSIFICATION
General
Damages as considered in the manuals, is any cross−sectional area change or
permanent distorsion of a structural member.
Use good judgment in determining the type of significant damage to structural
material.
The terms dent, crease, abrasion, gouge, nick, scratch, crack, corrosion, etc.
referred to elsewhere in the manuals, are defined on the next pages as a guide
for this determination, particularly with respect to the external skin of the air-
plane in panel areas.
Damages are classified in the following three categories:
1. Allowable Damage
Damage or distorsion which can be permitted to exist as it is or which may be
corrected by a simple procedure, such as stop drilling cracks or smoothing out
nicks is classified as allowable damage.
The extent of allowable damage for the major assemblies and component parts
are defined in the corresponding chapters of the Structural Repair Manual
(SRM).
2. Repairable Damage
Damages which exceeds the ”Allowable Damage” limits be repaired by cutting
out the damaged area of structural component and inserting or attaching a rein-
forcing piece. These specific repairs are to be found in each chapter of the
SRM.
3. Replacement of the Part

Replacement of the entire part is suggested when repair of the part is not prac-
tical or economical.
In some cases damage may necessitate replacement of the part.
These are specifically noted in other chapters of the manual. Replacement is
often advisable when damage to a complicated part is extensive or the dam-
aged part is less than 30 inches long.

SRM
Structure Repair Manual

Figure 32 Damage Classification

TABLE OF CONTENTS
DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
STRUCTURES - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MANUAL USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DAMAGE CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
AIRPLANE MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WDM USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EFFECTIVITY AND CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
PAGE BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AMM USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SAFETY ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MAINTENANCE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SYSTEM SCHEMATICS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REGISTRATION CROSS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . 30
WIRING DIAGRAM MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
EQUIPMENT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
WDM USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ILLUSTRATED PARTS CATALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ILLUSTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DISPATCH DEVIATIONS PROCEDURES GUIDE . . . . . . . . . . . . . . . . . . . 48
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
MASTER MINIMUM EQUIPMENT LIST (MMEL) . . . . . . . . . . . . . . . . . 50
REPAIR INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CONFIGURATION DEVIATION LISTS (CDL) . . . . . . . . . . . . . . . . . . . . 54
STRUCTURAL REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FRA US/E-1 Werner Jun 2005

Page i
TABLE OF FIGURES
Figure 1 Airplane Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2 Chapter Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3 Effectivity, Page Code and Configuration . . . . . . . . . . . . . 7
Figure 4 Page Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5 Organizational Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 7 Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 8 Troubleshooting - FMS General . . . . . . . . . . . . . . . . . . . . . 17
Figure 9 Safety Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 11 Maintenance Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 12 System Schematics Manual (SSM) . . . . . . . . . . . . . . . . . 25
Figure 13 Simplified Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 14 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 15 Registration Cross Reference . . . . . . . . . . . . . . . . . . . . . . 31
Figure 16 Wiring Diagram Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 17 Circuit Breaker List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 18 Wire List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 19 Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 20 Wiring Diagram 35−21−11 . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 21 Illustrated Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 22 Illustrated Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 23 IPC Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 24 DDPG Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 25 DDPG Section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 26 Item 21−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 27 CDL Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 28 CDL Example Chapter 33 . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 29 Standard Number System . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 30 Manual Number System . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 31 How to Use the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 32 Damage Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 33 Wire List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 34 Wiring Diagram 35−21−11 . . . . . . . . . . . . . . . . . . . . . . . . . 69
FRA US/E-1 Werner Jun 2005

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Boeing

Lufthansa Technical Training

Tel: +49 (0)40 5070 2520

FRA US/E WeR 3.3.05 Page: 1

FRA US/F do 10.04.98 Page: 2

Airplane Maintenance Manual

System TROUBLE Mainten. Removal Adjustment Inspection Cleaning Approved

AOM Volume I Volume II Volume III

Airplane Operation Manual Checklists Data

AIRPLANE MAINTENANCE MANUAL

FRA US/F do 1.5.98 Page: 4

Section/Subsystem (Power Control)

Figure 2 Chapter Numbering

EFFECTIVITY AND CONFIGURATIONS

subject matter, additional page blocks are added.

FRA US/F do 3.4.98 Page: 6

Non-Configuration Procedure Example

CONFIG 2 Procedure Example

Figure 3 Effectivity, Page Code and Configuration

FRA US/F do 1.4.98 Page: 8

Nomenclature Page Block

APPROVED REPAIRS (REP) 801 to 899

Figure 4 Page Blocks

General Testing − Three Levels

The functional test relates to component performance after installation and is

FRA US/F do 1.4.98 Page: 10

AIRCRAFT AIRFRAME STRUCTURE POWER PLANT

CHAPTERS 5−12 CHAPTERS 20−49 CHAPTERS 51−57 CHAPTERS 70−80

Figure 5 Organizational Breakdown

Troublshooting Example with table: is on the ground Effectivity: ...

1. General Figure 102

FRA US/E-1 WeR / NM 9.5.05 Page: 12

THE METHODE IS TO FOLLOW

Figure 6 Trouble Shooting

Trouble Shooting with table Example

TROUBLE PROBABLE CAUSE ISOLATION PROCEDURE REMEDY

Navigation light Bulb burned out Replace bulb. Replace bulb,

Navigation Lights Trouble Shooting Chart

FRA US/E-1 WeR / NM 9.5.05 Page: 14

5 SET THE DC METER SELECTOR 25 REPLACE THE TR3

Figure 7 Trouble Shooting

FMS Trouble Shooting

FRA US/E-1 WeR / NM 9.5.05 Page: 16

MENU LEGS DEP 1 2

. 0 +/− Z SP DEL / CLR

Other A/C Systems

Figure 8 Troubleshooting - FMS General

Example for a CAUTION

A example for a task with a WARNING is shown in the figure below.

FRA US/E-1 WeR 2.3.05 Page: 18

Figure 9 Safety Item

Standard Tools and Equipment

FRA US/E-1 WeR 7.3.05 Page: 20

Figure 10 Special Tools

This section shows why this maintenance tip is no longer in effect.

FRA US/E-1 WeR 23.4.05 Page: 22

Figure 11 Maintenance Tips

SYSTEM SCHEMATICS MANUAL

For example, a connector on the P320 panel is D32012.

FRA US/E-1 WeR 7.3.05 Page: 24

Figure 12 System Schematics Manual (SSM)

Simplified Schematics Pages

FRA US/E-1 WeR 8.3.05 Page: 26

HYDRAULICS HYDRAULICS MAIN GEAR