Commercial

Airplane
ATRAS 737
Group Service Bulletin

Number: 737-21-1101 Revision Transmittal Sheet

Date: February 1, 1990
Revision 1: September 26, 1991
ATA System: 2158

SUBJECT: AIR CONDITIONING - EQUIPMENT COOLING SYSTEM - DUCT REPLACEMENT

This revision includes all pages of the service bulletin.

SUMMARY

This revision is sent to change the Accomplishment Instructions to cut the fitting duct, if required, to give a
better fit. After the release of the initial service bulletin, some operators had clearance problems between the
fitting duct and the upper plenum duct. The duct is cut to make it shorter. This will prevent the clearance
problems.

Paragraph I.A., Effectivity, shows changes of airplane operators. Each operator should examine the
Effectivity paragraph for changes.

No more work is necessary on airplanes changed by the initial release of this service bulletin.

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

Pages with a revision number and date, but no vertical lines have no important changes.

REVISION HISTORY

Initial Release: February 1, 1990

Revision 1: September 26, 1991

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207
 Commercial
Airplane 737
Group Service Bulletin

Number: 737-21-1101 Summary

Date: February 1, 1990
Revision 1: September 26, 1991
ATA System: 2158

SUBJECT: AIR CONDITIONING - EQUIPMENT COOLING SYSTEM - DUCT REPLACEMENT

BACKGROUND Perform a leakage check and restore airplane to an

operable configuration.
Accomplishment of this service bulletin will reduce
the potential for equipment cooling duct joint COMPLIANCE
separation in the E3 rack plenum area on airplanes
with taped joints. No compliance time is specified.

Three operators have reported four occurrences of EFFECTIVITY

duct separation downstream of the E3 rack plenum
in the area of the taped joint. Review of the duct All 737-300, -400 and -500 airplanes line position
joint connection has revealed misalignment of the 1001 through 1714.
ducts of up to 0.75 inches which causes a preload
condition. Separation at the joint degrades the Manpower
integrity of the equipment cooling system.
Total Man hours 4 per Airplane
ACTION (PRR34784)
Elapsed Time 4 Hours
Gain access to the electronic equipment bay and
replace the upper plenum duct downstream of the MATERIAL INFORMATION
E3 rack. If preloading still exists at the interface
joint, remove the fitting duct on the E3 rack plenum, See Paragraph I.F for applicable terms and
cut the end of the duct and slot the fastener holes. conditions.

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207 Summary Page 1 of 1
 Commercial
Airplane 737
Group Service Bulletin

Number: 737-21-1101
Date: February 1, 1990
Revision 1: September 26, 1991
ATA System: 2158

SUBJECT: AIR CONDITIONING - EQUIPMENT COOLING SYSTEM - DUCT REPLACEMENT

I. PLANNING INFORMATION

A. Effectivity

1. Airplanes

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

An equivalent change will be incorporated in production in accordance with PRR34784 on

applicable airplanes other than those listed below.

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

CUSTOMER
GROUP VARIABLE NUMBER

AER LINGUS (ARL)

PP951-PP952
AIR BELGIUM (ABL)
PP380 PW061
AIR BERLIN USA (BER)
PP822
AIR CHINA (BEJ)
PP521-PP522
AIR EUROPA (ARE)
PP501-PP502 PP835 PP846 PP935 PP947
AIR EUROPE (INT)
PW111 PW112 PW502
AIR EUROPE SCANDANAVIA (ANW)
PP904 PP907
AIR UK, LTD. (AUK)
PW001
ALOHA (ALO)
PP730 PP733
AMERICA WEST AIRLINES, INC. (AMW)
PP181-PP197 PP378 PP381 PP727 PP732 PP891-PP899
PP901 PP903 PP931-PP934 PP936

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 BOEING SERVICE BULLETIN 737-21-1101

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (continued)

CUSTOMER
GROUP VARIABLE NUMBER
AMERICAN AIRLINES, INC. (AAL)
PP161-PP168
ANSETT AIRLINES OF AUSTRALIA (ANS)
PQ026-PQ041
ASIANA AIRLINES (AAR)
PW005 PW007-PW009 PW011 PW013
AUSTRALIAN AIRLINES LIMITED (AUS)
PQ001-PQ014
AVENSA (AVN)
PM383
AVIATECA (AVT)
PP352 PP384
BRITANNIA AIRWAYS, INC. (BRI)
PP201-PP205
BRITISH MIDLAND (BMA)
PP908-PP909 PP915-PP916 PW004 PW006 PW501
CHINA SOUTHWEST AIRLINES (XIN)
PP631-PP634
CONTINENTAL AIRLINES, INC. (CAL)
PP671-PP699 PP701-PP726
CORSE AIR INTERNATIONAL (COR)
PP831 PP838
DAN AIR (DAN)
PP351 PP353 PW091-PW092
DELTA AIR LINES, INC. (DAL)
PP231-PP243
DUKE FARMS (DFI)
PP991
GARUDA INDONESIAN AIRWAYS (GIA)
PQ282
GERMANIA FLUGGESELLSCHAFT MBH (GER)
PP503 PQ231-PQ236
HAPAG LLOYD (HAP)
PW511-PW513
ICELANDAIR (ICE)
PW561
INTER EUROPEAN AIRWAYS (IER)
PP841-PP842

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 BOEING SERVICE BULLETIN 737-21-1101

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (continued)

CUSTOMER
GROUP VARIABLE NUMBER
INTERNATIONAL LEASE FINANCE (ILF)
PP379-PP382
ISTANBUL AIRLINES (IST)
PW002
JUGOSLOVENSKI AEROTRANSPORT (JAT)
PP771-PP779
KLM ROYAL DUTCH AIRLINES (KLM)
PP861-PP873
KOREAN AIR FORCE (KAF)
PP221
LADECO (LDE)
PP946
LAUDA AIR LUFTFAHRTGESELLSCHAFT M.B.H. (LAL)
PP851-PP852
LINJEFLYG AB (LNJ)
PQ281
LUFTHANSA GERMAN AIRLINES (DLH)
PQ051-PQ068 PQ086-PQ092
MAERSK AIR (MRS)
PP504-PP507
MERIDIANA, CIA. ESPANOLA DE AVIATION (UNV)
PP731
MONARCH AIRLINES, LTD. (MON)
PM381 PP821 PP823-PP824 PP832 PP845 PP913-PP914
NORTJET (EUS)
PW010 PW012
PAKISTAN INTERNATIONAL AIRLINES CORP. (PIA)
PP281-PP286
POLY TECHNOLOGIES, INC. (PTI)
PP728-PP729
SABENA BELGIAN WORLD AIRLINES (SAB)
PP961-PP967
SOUTHWEST AIRLINES CO. (SWA)
PP101-PP145
T A PORTUGUESES (TAP)
PP984 PQ301-PQ303
TRANS EUROPEAN AIRWAYS (TEA)
PM382 PP840 PP948 PQ221-PQ225
TRANSAVIA AIRLINES (TAV)
PP801-PP806

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 BOEING SERVICE BULLETIN 737-21-1101

LISTING BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER, (continued)

CUSTOMER
GROUP VARIABLE NUMBER

TRANSBRASIL AIRLINES INC. (TBL)

PP825-PP826 PP836-PP837 PP843-PP844 PP847-PP848 PQ241-PQ243
UNION DE TRANSPORTS AERIENS - UTA (UTA)
PP902 PP910-PP912 PS641
UNITED AIR LINES, INC. (UAL)
PQ101-PQ157
USAIR, INC. (USA)
PP001-PP010 PP012-PP049 PP376-PP377 PP383 PP401-PP440 PP471-PP475
PV001-PV010 PV012-PV016
VARIG AIRLINES (VAR)
PP839 PP905-PP906 PP981-PP982 PQ251-PQ255
VASP (VSP)
PP301-PP305 PP827 PP833-PP834
VIVA AIR (VIV)
PP169 PP391-PP393 PP983
YUNNAN PROVINCIAL IMPORT & EXPORT CORP. (YUN)
PP651-PP652

LISTING BY VARIABLE NUMBER

PM381-PM383 PP001-PP049 PP101-PP145 PP161-PP169 PP181-PP197 PP201-PP205

PP221 PP231-PP243 PP281-PP286 PP301-PP305 PP351-PP353 PP376-PP384
PP391-PP393 PP401-PP440 PP471-PP475 PP501-PP507 PP521-PP522 PP631-PP634
PP651-PP652 PP671-PP699 PP701-PP733 PP771-PP779 PP801-PP806 PP821-PP827
PP831-PP848 PP851-PP852 PP861-PP873 PP891-PP899 PP901-PP916 PP931-PP936
PP946-PP948 PP951-PP952 PP961-PP967 PP981-PP984 PP991 PQ001-PQ014
PQ026-PQ041 PQ051-PQ068 PQ086-PQ092 PQ101-PQ157 PQ221-PQ225 PQ231-PQ236
PQ241-PQ243 PQ251-PQ255 PQ281-PQ282 PQ301-PQ303 PS641 PV001-PV016
PW001-PW013 PW061 PW091-PW092 PW111-PW112 PW501-PW502 PW511-PW513
PW561

2. Spares

Examine your spares supply for the parts identified in Paragraph II.D., Existing Parts Accountability.
If any parts are found, refer to Paragraph II.D., Existing Parts Accountability, for the recommended
use.

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 BOEING SERVICE BULLETIN 737-21-1101

B. Reason

Accomplishment of this service bulletin will reduce the potential for equipment cooling duct joint
separation in the E3 rack plenum area on airplanes with taped joints.

Three operators have reported four occurrences of duct separation downstream of the E3 rack plenum

Revision 1 is sent to change the Accomplishment Instructions to cut the fitting duct, if required, to give
a better fit. After the release of the initial service Bulletin, some operators had clearance problems
between the fitting duct and the upper plenum duct. The duct is cut to make it shorter. This will prevent
the clearance problems.

C. Description

Access is gained to the electronic equipment bay and the elbow duct downstream of the E3 rack is
replaced. If preloading still exists at the interface joint, the fitting duct on the E3 rack plenum is
removed and cut, and the fastener holes are slotted. A leakage check is performed and the airplane is
restored to an operable configuration.

No more work is necessary on airplanes changed by the initial release of this service bulletin.

D. COMPLIANCE

No compliance time is specified.

E. Approval

This service bulletin has been reviewed by the Federal Aviation Administration (FAA) and the repairs
and modifications herein comply with the applicable Federal Aviation Regulations (FAR's) and are FAA
approved.

F. Manpower

Approximately 4 man-hours are required to accomplish this duct replacement per airplane.

Feb 1/90 737-21-1101

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 BOEING SERVICE BULLETIN 737-21-1101

G. Material - Price and Availability

The parts identified in Paragraph II.A may be procured through normal spares channels. Accordingly,
price and delivery data are not included in support of this bulletin.

H. Tooling - Price and Availability

None

I. Weight and Balance

None

J. References

1. Existing Data:

a. Engineering Change Memo PRR34784

b. 737 Maintenance Manual Subject 24-20-00

c. 737 Structural Repair Manual Chapter 51

2. Data supplied in support of this service bulletin:

None

K. Publications Affected

Publication Chapter-Section

737 Illustrated Parts Catalog 25-57

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 BOEING SERVICE BULLETIN 737-21-1101

II. MATERIAL INFORMATION

A. Parts Necessary For Each Airplane

The following parts may be obtained as noted in Paragraph I.F and are required for each airplane.

Part Number or
Quantity Specification Nomenclature

1 65-78229-18 Duct Assembly

6 BACW10P42S Washer

6 NAS1801-3-9 Screw

1 pint BMS 5-92, (a) Sealant

Type I or III

(a) See 737 Maintenance Manual Subject 20-30-11 for material sources.

B. Parts Required to Modify Spares

None

C. Special Tools and Equipment Required

No special tools or equipment are required to accomplish this bulletin. Maintenance and overhaul tools
may be required per any manuals that are listed in Paragraph I.I., References, of this bulletin.
Operators should review their tool inventory to ensure tool availability.

Feb 1/90 737-21-1101

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 BOEING SERVICE BULLETIN 737-21-1101

D. Existing Parts Accountability

The following parts are affected by this service bulletin. The quantity (Qty) column lists the quantity
affected per airplane.

Existing New Part

Part Number Nomenclature Qty DC Number PNC IC

65-78229-5 Duct Assembly 1 DIS 65-78229-18 S C

65-78236-8 Duct Assembly 1 RWK 65-78236-12 X,S C

69-51834-6 Orifice 1 DIS - - B

DC Disposition Code

DIS - Discard Part

RWK - Rework existing part in accordance with this service bulletin.

PNC Part Number Code

S - Superseding or new equivalent part number.

X - The function, fit, and dimensions of the existing part and the new part are
equivalent but not fully the same. The operator can use the new part
number to identfy the changed part.

IC Interchangeability Code

B - Removed part: No direct replacement.

C - Conditionally Interchangeable: Installation of superseded part negates the

intent of this service bulletin.

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 BOEING SERVICE BULLETIN 737-21-1101

III. ACCOMPLISHMENT INSTRUCTIONS

NOTES:

1. The paragraphs identified with letters give the general work instructions and the necessary tests.
The instructions identified with numbers on the figure(s) give the recommended sequence of steps.

2. Unless specified differently, these dimensions and tolerances are used:

- All linear dimensions are in inches

- Tolerance on linear dimensions other than rivet and bolt edge margin is plus or minus 0.03 inch
- Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch
- The hole dimensions for standard solid rivets are found in 737 Structural Repair Manual Chapter 51
- The torque limits to tighten nuts and bolts are found in 737 Structural Repair Manual Chapter 51.

3. Obey all warnings and cautions in the specified manual sections.

A. Remove electrical power from the airplane per 737 Maintenance Manual Subject 24-22-00.

B. Gain access to the electronic equipment bay and modify the equipment cooling ducts per Figure 1.

C. Restore electrical power to the airplane per 737 Maintenance Manual Subject 24-22-00.

D. Verify that there is no noticeable leakage from the equipment cooling ducts at the modified joints.

E. Close the electronic equipment bay door and restore airplane to an operable configuration.

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 BOEING SERVICE BULLETIN 737-21-1101

FIGURE 1. EQUIPMENT COOLING DUCT MODIFICATION

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 BOEING SERVICE BULLETIN 737-21-1101

FIGURE 1. EQUIPMENT COOLING DUCT MODIFICATION

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FIGURE 1. EQUIPMENT COOLING DUCT MODIFICATION

Feb 1/90 737-21-1101

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 BOEING SERVICE BULLETIN 737-21-1101

The instruction number(s) shown below agree with the number(s) shown inside the circle symbol(s) in the
figure.

1 Remove upper plenum duct 65-78229-5 from inlet plenum by removing tape at joint connecting upper
plenum duct to fitting duct and remove bolt BACS12CB3-8, washer BACW10P68S and nut
BACN10JC3 (8 places). Retain bolts, washers and nuts for reinstallation and discard duct.

2 Install upper plenum duct 65-78229-18 using retained fasteners. This duct has slotted fastener
locations so that duct can be adjusted to alleviate preload. If duct can be installed without any
preloading, bond joint between upper plenum duct and fitting duct using sealant BMS 5-92, Type I or III
and no further action is required. If preloading or tight fit continues, do Circle Notes 3 through 7.

3 Loosen the upper plenum duct at the flange and turn it to make clearance between it and the fitting
duct.

4 Make a mark on the fitting duct 65-78236-8 at the location where the new upper plenum duct
65-78229-18 ends, as shown.

5 Remove fitting duct 65-78236-8 from E3 rack by removing clamp STBC10GG-114 and fasteners (6
places). Discard the fasteners and orifice 69-51834-6 and retain clamp for reinstallation.

6 Cut the fitting duct so it is one inch longer than the mark made in Circle Note 4.

7 Slot the fastener locations on the fitting duct using the dimensions shown (6 places). Mark the
reworked fitting duct to show that the service bulletin has been accomplished.

8 Reinstall the fitting duct using screw NAS1801-3-9 and washer BACW10P42S (6 places) and bond the
joint between the upper plenum duct and the fitting duct using sealant BMS 5-92, Type I or III and
reinstall clamp STBC10GG-114 on the inboard side.

FIGURE 1. EQUIPMENT COOLING DUCT MODIFICATION

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 Commercial
Airplane 737
Group Service Bulletin

Number: 737-21-1101 Evaluation Form

Date: February 1, 1990
Revision 1: September 26, 1991
ATA System: 2158
Prepared By: Brad Styner

SUBJECT: AIR CONDITIONING - EQUIPMENT COOLING SYSTEM - DUCT REPLACEMENT

Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data
that you give us to improve the quality of our service bulletins. Please include data about these or other
items:

- Did this service bulletin meet your estimate of quality?

- How easy is this service bulletin to understand?
- Are the Planning Information, Material Information and Accomplishment Instructions satisfactory?
- Will you do this service bulletin fully? If not, please tell us why.
- Is the Manpower estimate satisfactory?

NOTE: Please do not use this evaluation form to tell us to make changes to your manuals. To make these
changes, please use a Publication Change Request (PCR) form.

Please give us this data:

OPERATOR: TODAY'S DATE:
PREPARED BY: TITLE:
ORGANIZATION: TELEX CODE:
TELEPHONE NUMBER:

COMMENTS:

If you have other comments please use the other side. Thank you for the time you used to complete this
form.
Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form
directly to this address:
R.G. Kelsey, Manager
Service Bulletin Engineering
Boeing Commercial Airplane Group
P.O. Box 3707, Mail Stop 2L-02
Seattle, WA 98124-2207

BOEING COMMERCIAL AIRPLANE GROUP P.O. BOX 3707 SEATTLE, WASHINGTON 98124-2207