CARRIAGE OF HORSES OR OTHER ANIMALS

Document No: S21.AMMS-0018 Issue: 1

Dated: 5th April 2019

Boeing 737 -400

Instructions for Continued Airworthiness Including Aircraft Maintenance Manual Supplement for Aircraft Embodied With:

CARRIAGE OF HORSES OR OTHER ANIMALS

STC Twenty One Limited The Waldorf Centre 1290 London Road

Alvaston Derby DE 24 8QP United Kingdom

The technical content of this document is approved under the authority of DOA nr. EASA. 21J.198

The copyrights of this document are reserved by STC Twenty One Limited. It is provided in confidence on the condition that it is not copied, reproduced or disclosed either wholly or in part, without the consent, in writing, of STC Twenty One Limited. It is supplied in confidence, and commercial security on its contents must be maintained. It must not be used for any purpose other than for which it is supplied, nor may information contained in it be disclosed to unauthorised persons. It must not be reproduced in whole or in part without permission in writing from the owners of the copyright.

TRANSMITTAL NOTICE Page ii Issue 1 – 5th April 2019 © STC Twenty One Limited. S21.47.REP.043 Issue 4 12-02-2018

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1. TRANSMITTAL NOTICE

To: All holders of this STC Twenty One Limited Document This Aircraft Maintenance Manual (including Instructions for Continued Airworthiness) Supplement is provided in electronic format (PDF). This should be filed together with the affected manual(s) IAW the operator’s approved procedures for technical publication filing and retention. In the event that this Aircraft Maintenance Manual (including Instructions for Continued Airworthiness) Supplement is revised, it will supersede any previous revision in its entirety and any previous revisions should be disregarded. Record the embodiment of above referenced Technical Publication and date of insertion on the Record of Supplements/Revisions. This should be filed together with the affected manual(s) IAW the operator’s approved procedures for technical publication filing and retention.

This Manual Revision/Supplement is true and accurate at the time of issue. This revision/supplement is issued by STC Twenty One Ltd and complies with relevant EASA requirements. Any further changes to the aircraft affecting these publications should be reported to STC Twenty One Ltd.

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© STC Twenty One Limited. S21.47.REP.043 Issue 4 12-02-2018

MAINTENANCE REPORTING Page iii

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2. MAINTENANCE REPORTING FORM

STC Twenty One The Waldorf Centre, 1290 London Road, Alvaston, Derby, UK, DE24 8QP Fax: +44 (0)1332 576831 Email: [email protected]

Maintenance Reporting Form Deal With One Subject Only

Name: Position:

Contact Telephone No.: Contact Email:

Question/Suggestion

Date: Change/Repair Number: S21.25-13-1664 Use this form to notify STC Twenty One Limited of any difficulties or problems associated with the information contained within this Supplemental Manual.

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4. RECORD OF REVISIONS

Note: Revisions to this manual will be made as a complete new issue and recorded in this record of re-issues.

Revision No. REVISION DATE DESCRIPTION OF CHANGE

Initial issue 05/04/2019 INITIAL issue of manual

Page viii Issue 1 – 5th April 2019


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5. TABLE OF CONTENTS CARRIAGE OF HORSES OR OTHER ANIMALS .................................................................................................. i

1. TRANSMITTAL NOTICE .................................................................................................................... ii

2. MAINTENANCE REPORTING FORM ............................................................................................... iii

3. APPROVAL SHEET ........................................................................................................................... v

4. RECORD OF REVISIONS ................................................................................................................. vii

5. TABLE OF CONTENTS ..................................................................................................................... ix

AWL: Airworthiness Limitations ............................................................................................................... 1

1. General ........................................................................................................................................... 2

00 INTRODUCTION .................................................................................................................................... 1

1. 00 TABLE OF CONTENTS ................................................................................................................. 2

2. General ........................................................................................................................................... 3

A) Statement of Purpose ................................................................................................................... 3

B) System / Component Description, Operation and Location ........................................................ 4

C) Applicability/Effectivity ................................................................................................................ 5

D) Contact Details ............................................................................................................................. 5

E) Definitions & Abbreviations ......................................................................................................... 6

F) General Safety Precautions .......................................................................................................... 6

G) Units of Measure .......................................................................................................................... 6

H) References .................................................................................................................................... 7

I) Distribution ................................................................................................................................... 7

05 TIME LIMITS, MAINTENANCE CHECKS ................................................................................................. 1

1. CHAPTER 05 TABLE OF CONTENTS ................................................................................................. 2

2. Time Limits And Maintenance Checks ........................................................................................... 3

A) General ......................................................................................................................................... 3

B) Table Definitions ........................................................................................................................... 3

C) Scheduled Maintenance Task List ................................................................................................ 5

11 PLACARDS AND MARKINGS ................................................................................................................. 1


3. Placards and Markings ................................................................................................................... 3

A) General ......................................................................................................................................... 3

B) Placard Identification Table .......................................................................................................... 3

25 EQUIPMENT AND FURNISHINGS .......................................................................................................... 1


2. Description, Location and Operation ............................................................................................. 3

A) General ......................................................................................................................................... 3

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3. Trouble Shooting ........................................................................................................................ 101

4. Flight Compartment Emergency Light Maintenance Practices .................................................. 201

4. Tooling ........................................................................................................................................ 401

5. Repairs ........................................................................................................................................ 801

6. Special Procedures ......................................................................................................................... 1

(1) Girt bar and Escape slide floor bracket maintenance practices ................................................... 1

(2) Escape slide assembly description /operation and Maintenance practices ................................ 1

(3) Additional Notes for the Carriage of Animals other than Horses ................................................ 1

(4) Seating Configuration Options ..................................................................................................... 2

(5) Required Emergency Equipment for Carriage of Horses or Other Animals ................................. 5

(6) Loading layouts - Hoarse and other animal stalls ........................................................................ 7

(7) Role Change – “CARGO” to “CARRIAGE OF HORSES OR OTHER ANIMALS” ............................... 11

(a) General Pallet................................................................................................................... 11

(b) In the Cockpit ................................................................................................................... 13

(c) At the rear Lead Animal Handler seating station............................................................. 13

(8) Role Change – “CARRIAGE OF HORSES OR OTHER ANIMALS” to “CARGO” ............................... 15

(a) General ............................................................................................................................. 15

(b) In the Cockpit ................................................................................................................... 15

(c) In the Main Cargo Compartment ..................................................................................... 15

(d) Off the Aircraft ................................................................................................................. 15

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CHAPTER

AWL

AWL: Airworthiness Limitations

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CHAPTER

00

00 INTRODUCTION

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1. 00 TABLE OF CONTENTS

00 INTRODUCTION .................................................................................................................................... 1

1. 00 TABLE OF CONTENTS ................................................................................................................. 2

2. General ........................................................................................................................................... 3

A) Statement of Purpose ................................................................................................................... 3

B) System / Component Description, Operation and Location ........................................................ 4

C) Applicability/Effectivity ................................................................................................................ 5

D) Contact Details ............................................................................................................................. 5

E) Definitions & Abbreviations ......................................................................................................... 6

F) General Safety Precautions .......................................................................................................... 6

G) Units of Measure .......................................................................................................................... 6

H) References .................................................................................................................................... 7

I) Distribution ................................................................................................................................... 7

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2. General

A) Statement of Purpose

This Aircraft Maintenance Manual (AMMS) including Instructions for Continued Airworthiness (ICA) manual describes the changes to the aircraft as a result of embodying S21.25-13-1664, and provides the information required to ensure continued airworthiness.

The data herein is applicable only to these changes; for all other parts and systems of the aircraft and for any information not included herein, refer to the Aircraft Maintenance Manual and associated documents.

Chapters 4 through 99 of this supplement manual contain the Maintenance instructions for the ongoing airworthiness of the installed design change and are broken down into ATA Chapters for the easy incorporation into existing aircraft maintenance manuals.

The format of these chapters is broken down into to typically include the following sections:-

• 001 – 099 System/Component description and System/Component Location;

• 101 – 199 Troubleshooting

• 201 – 299 Maintenance Practises;

• 301 – 399 Servicing;

• 401 – 499 Component removal / installation;

• 501 – 599 Adjustment / test;

• 601 – 699 Inspection / check;

• 701 – 799 Cleaning / painting;

• 801 – 899 Repairs;

• 901 – 999 Maintenance procedures

Where appropriate, existing type certificate holder data may be referred to if there are no deviations required by STC Twenty One Limited.

Note: If there are no Maintenance Instructions, the relevant section(s) will be omitted from the relevant chapter.

Additional information regarding the Line replaceable parts required to maintain the design change can be found in STC Twenty One document S21.IPCS-0018

Additional information regarding any introduced changes to the wiring of the aircraft can be found in STC Twenty One document S21.WDMS-0016


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B) System / Component Description, Operation and Location

1) Design change S21.25-13-1664 has activated a freighter converted aircraft for the carriage of horses or other animals and animal handlers.

2) All electrical wiring provisions have been installed via STC Twenty One limited minor design change S21.25-13-1663 and the following mechanical provisions have been installed via minor design change S21.25-13-1665. These two minor design changes will be prerequisites of this design change.

• 9 Ordinance Signs

• 9 PA Speakers

• 1 Warning Horn

• 1 Emergency Lighting

• 3 Emergency Battery Packs

• AFT Service Door Reactivation

• 1 Lead Animal handler Panel Installation

• 2 Over Door Emergency exit sign installation

• 1 Role Change panel installation

3) Additional information regarding the Line replaceable parts required to maintain the design change can be found in STC Twenty One document S21.IPCS-0018

4) Additional information regarding any introduced changes to the wiring of the aircraft can be found in STC Twenty One document S21.WDMS-0016

5) This design change has been installed onto a Boeing 737-400 aircraft converted to a freighter by Aeronautical Engineers, INC (AEI) under EASA STC 10015732 (EASA.IM.A.S.01754), with a Smoke Detection and Fire Suppression System installed under Advanced Aircraft Extinguishers Ltd (AAE) EASA STC 10015780 and a Cargo Loading System installed under Ancra EASA STC 10033161.

6) In order to facilitate the carriage of animal handlers when transporting horses or other animals in a cargo aircraft, this STC has activated/terminated all provisioned wiring and introduced seating on removable pallets for up to 19 animal handlers.

7) The seating pallets (including seats & life vests) have been located and restrained by the existing cargo handling system at the three most rear positions.

8) The rework to the aircraft consists of the following, all activation items are provisioned under the previous mentioned minor design changes.;

• Activation of the left and right hand rear door escape slides requiring the reinstallation of girt-bar attachment positions at both door positions and re-installation of the original Boeing build standard door mounted emergency escape slides.

• Activation of passenger address loud speakers and a means of two-way communication and calling with the flight deck (installed adjacent to one animal handler seat position).

• Activation of decompression warning lamps visible from the designated animal handler seating positions and at each location where the animal handlers will be positioned to attend horses and other animals during flight.

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• Activation of cabin ordinance signs visible from all animal handler seat positions and at each location where the animal handlers are positioned to attend horses and other animals during flight.

• Activation of emergency light units and illuminated exit signs above the left and right hand rear entry doors.

• Any placards required by any EASA special conditions. All placards for the certification basis of this design change or operating rules will be installed under the provisioning design change.

• Installation of supplemental oxygen by means of individual oxygen cylinders installed beneath each animal handler seat.

• Installation of walk round oxygen and emergency equipment stowage’s onto a seating pallet.

• Installation of GIRT bar catches and rework to the existing cargo handling system to allow the fitment of the girt bar catches.

• Installation of emergency batteries.

Note: The operator will be responsible for the selection of animal handlers with regard to training and security. Operational approval for the aircraft to operate in this role will be the responsibility of the operator and their National Airworthiness Authority.

Note: It is intended that purpose built horse or other animal boxes previously approved will be utilised in this design change.

Note: The containers must comply with section 8 of the IATA live animals’ regulations. Limitations as listed within this manual( chapter 25 section 6).

Note: The minimum aisle space for access to the livestock handlers seating positions must be

maintained throughout the compartment in accordance with the requirements defined in contained in this manual (chapter 25 section 6).

C) Applicability/Effectivity

This change is applicable to aircraft shown in the Aircraft Effectivity box (found on the bottom left hand corner of each page) or found in the table below.

24440 25097 25105 25110 25111 25147 28886

28892 28893 29202 29203 29270

Note: Some pages Aircraft Effectivity box may not show all aircraft MSN’s, this is due to aircraft specific

parts or differences in individual aircraft configurations. The Applicability box shows all aircraft that this design change is applicable to.

D) Contact Details

Any corrections or amendments to this supplement, arising from operational use, should be advised to STC Twenty One Limited, using the Maintenance Findings Form Page 2 of this supplement maintenance manual to enable any necessary remedial action to be taken.

STC Twenty One Limited


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The Waldorf Centre 1290 London Road Alvaston Derby DE24 8QP UK Tel: +44 (0)1332 576830 Fax: +44 (0)1332 576831 Email:[email protected]

E) Definitions & Abbreviations

Definitions:

WARNING! Items for which procedures, practices, and conditions with respect to maintenance or installation that if not strictly observed could result in injury to or death of personnel or property damage.

CAUTION! Items for which procedures, practices, and conditions with respect to maintenance or installation that if not strictly observed could result in damage to equipment or property.

Note: Items on which special emphasis is placed as a means of bringing that information to the attention of the maintenance technician.

Abbreviations:

AMM Aircraft Maintenance Manual

AMMS Aircraft Maintenance Manual Supplement

CMM Component Maintenance Manual

EASA European Aviation Safety Agency

EWIS Electrical Wiring Interconnect Systems

ICA Instructions for Continued Airworthiness

ICAS Instructions for Continued Airworthiness Supplement

IPCS Illustrated Parts Catalogue Supplement

STC Supplemental Type Certificate

WDMS Wiring Diagram Manual Supplement

F) General Safety Precautions

Observe all general safety precautions concerning ground power operations.

Open and collar all circuit breakers during inspections, component removals and wiring troubleshooting procedures (other than power checks or normal operational tests).

G) Units of Measure

Imperial or Metric unless otherwise stated.

mailto:[email protected]

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H) References

The following list of reference documentation supplements data presented within this manual. Although not required these documents enhance the operators ability to provide continued airworthiness to the aircraft when performing maintenance and/or troubleshooting.

Applicable Reference List*

Description: Doc No. Vendor Contact details.

PROVISIONING MANUALS BY STC21 DESIGN CHANGE S21.25-13-1665

S21.AMMS-0016 S21.IPCS-0016

STC Twenty One The Waldorf Centre, 1290 London Road, Alvaston, Derby, UK, DE24 8QP Fax: +44 (0)1332 576831 Email: [email protected]

Note! *Latest revision available at time of writing.

I) Distribution

The aircraft operator is furnished these Instructions for Continued Airworthiness upon the embodiment of the design change to which they relate on the aircraft identified in the applicability section, at which time it becomes part of the permanent aircraft record.

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CHAPTER

05

05 TIME LIMITS, MAINTENANCE CHECKS


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1. CHAPTER 05 TABLE OF CONTENTS

05 TIME LIMITS, MAINTENANCE CHECKS .................................................................................................. 1


2. Time Limits and Maintenance Checks............................................................................................ 3

A) General .......................................................................................................................................... 3

B) Table Definitions ........................................................................................................................... 3

C) Scheduled Maintenance Task List ................................................................................................. 5

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2. Time Limits and Maintenance Checks

A) General

These are tasks such as treatments, inspections, component/fluid changes or restorative actions that are recommended to be carried out within specified time limits. Failure to carry out these tasks, whilst not degrading the airworthiness of the aircraft below an acceptable level, will result in degraded system/component performance or premature system/component failure. Each task has a unique identifier (Task Number). Task numbers, task descriptions, aircraft zones and implementation thresholds/periodicities are listed in tabular form. Where scheduled maintenance is defined by a component manufacturer and is subject to change, the appropriate manufacturers Component Maintenance Manual (CMM) or other equivalent document shall be referenced. In such cases it is the responsibility of the operator to incorporate these instructions into their Aircraft Maintenance Programme (AMP). If there are no Scheduled Maintenance Items, NONE, shall be identified in this section.

B) Table Definitions

SM/TASK NUMBER Each task in the Scheduled Maintenance section is identified with a unique number identifier.

S21.AMMS REFERENCE Airplane Maintenance Manual procedure which supports the scheduled maintenance requirement: S21.AMMS-xxxx-xx-xx. Or the original aircraft AMM which references the maintenance procedure. The first number lists the associated STC21.AMMS The second set of numbers shows the ATA chapter in the manual including Chapter. The third set of numbers shows the relevant section within the chapter.

TASK LUB = LUBRICATION - Consumable replenishment by lubricating. SVC = SERVICING - Consumable replenishment by servicing. OPC = OPERATIONAL CHECK - A failure finding task to determine if an item is fulfilling its intended purposes. Does not require quantitative tolerances. VCK = VISUAL CHECK - A visual failure finding task through observation to determine if an item is fulfilling its intended purpose. Does not require quantitative tolerances. GVI = INSPECTION - GENERAL VISUAL - A visual examination that will detect obvious unsatisfactory conditions


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FNC = FUNCTIONAL CHECK - A quantitative check to determine if one or more functions of an item performs within specified limits. This is a potential failure finding task. DET = INSPECTION - DETAILED - An intensive visual examination of a specified detail, assembly, or installation. A potential failure finding task. RST = RESTORATION - Reworking, replacement of parts or cleaning necessary to return an item to a specific standard. DIS = DISCARD - The removal from service of an item at a specified life limit.

FREQUENCY Task intervals are expressed in terms of frequency and usage parameters such as calendar and flight cycles.

TASK DESCRIPTION The type of inspection that is accomplished and a description of the task to be performed. Applicability, access and interval notes are to be listed here to provide additional explanation for the other columns where “NOTE” is used

EFF Here will list the applicable aircraft that each task is applicable to by Manufactures Serial Number (MSN).

• When groups of aircraft will be affected they will be listed by group in the Applicability table in section 2.

• When all aircraft listed in the Applicability table in section 2, will be affected the word “ALL” will be in this column.

• When individual aircraft will be affected they will be listed by individual MSN.

TASK MAN HOURS Estimated labour hours required to perform the task. These do not include:

• Docking the aircraft

• Positioning/removing work stands

• Access Door/Panel removal and installation

• Cabin equipment, lining, floor panel and installation and removal

• Correcting discrepancies found while performing the task These Estimates are based on the use of skilled personnel and assume the inspections in the same zone with a common frequency will be performed together.

Comments Additional instructions to aid in the accomplishment of the task including actions to be taken and locations of items listed .

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C) Scheduled Maintenance Task List

SM /TASK NO

S21.AMMS REFERENCE TASK FREQUENCY TASK DESCRIPTION EFF TASK MAN

HOURS COMMENTS

1 S21.AMMS-0018-11-03 VCK

Prior to each horse or

other animal charter flight

Visually inspect each placard applied to the cargo compartment for integrity of adhesive.

ALL ½ Replace any defaced or peeling signs.

2 S21.AMMS-0016-25-04 VCK ‘A’ Check Visually inspect each Ordinance Sign mounting panel for damage, corrosion and security and integrity of signage.

ALL ½

Cargo compartment ceiling stations 500+12 starboard, 663.75+10.6 starboard and 847+5.5 port.

3 S21.AMMS-0016-25-04 VCK ‘A’ Check Visually inspect communications panel for damage, corrosion and security and integrity of switches and lamp.

ALL ½ Cargo compartment right hand sidewall station 1003

4 BOEING AMM 737 -300/-400/-500 25-61-51-201.

VCK ‘A’ Check

Visually inspect rear left and right hand entrance door girt bar mounting brackets for damage, corrosion and free operation of the retention plate return springs.

ALL ½ Cargo compartment right and left entrance door floor panels

5 BOEING AMM 737 -300/-

400/-500 25-61-35. VCK ‘A’ Check

Visually inspect rear left and right hand entrance door escape slide stowages for damage to cover or girt strap.

ALL ½ Cargo compartment right and left entrance door

6 S21.AMMS-0018-25-06 VCK ‘A’ Check Visually inspect safety equipment and portable oxygen stowage boxes for damage and security of attachment fittings.

ALL ½ Stowages are attached to the left hand side of the forward seat pallet.

7 S21.AMMS-0018-25-06 VCK ‘A’ Check Visually inspect seat pallets for damage, cracks and corrosion.

ALL 1 When seat pallets are in continuous use on the aircraft.


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8 S21.AMMS-0018-25-06 VCK Every 3 Months

Visually inspect seat pallets for damage, cracks and corrosion.

ALL 1 When seat pallets are in storage

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CHAPTER

11

11 PLACARDS AND MARKINGS


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11 PLACARDS AND MARKINGS .................................................................................................................. 1


3. Placards and Markings ................................................................................................................... 3

A) General .......................................................................................................................................... 3

B) Placard Identification Table .......................................................................................................... 3

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3. Placards and Markings

A) General

(1) With reference to the figure 001 paint the following markings and install placards onto the aft entry and aft service doors.

B) Placard Identification Table

Item Part/Placard Number Placard Wording/ Description Location

A Colour grey BAC707. 2 inch band around the doors See Figure 001

B BACM9E2AA ‘EMERGENCY EXIT placard, See Figure 001

C BACM9L2BN ‘EXIT’ See Figure 001

D BACM9L2AZ ‘OPEN’ See Figure 001

E BACM9S1AR Door handle opening arrow See Figure 001

F BAC27DPA4958 Door operation instructions See Figure 001

G BAC27DPA4958 ‘CAUTION’ placard, See Figure 001

H

11-13-10042-3* & 11-13-10042-4*

CONFIGURATION PLACARD (12 or

19 PAX) See figure 1

11-13-10042-3* & 11-13-10042-4*

CONFIGURATION PLACARD (4

PAX) FWD entry door

11 11-13-10042-11 EXIT SIGN - STARBOARD See Figure 002

12 11-13-10042-12 EXIT SIGN -PORT See Figure 003

13 BAC29PPS50650 NO SMOKING See Figure 003

*Dependant on configuration. Figure 001.

AFT ENTRY DOOR PLACARDS AND MARKINGS AFT SERVICE DOOR PLACARDS AND MARKINGS

H


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Figure 002

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Figure 003

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CHAPTER

25 25 EQUIPMENT AND FURNISHINGS

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25 EQUIPMENT AND FURNISHINGS .................................................................................... 1

1. CHAPTER 25 TABLE OF CONTENTS .......................................................................... 2

2. Description, Location and Operation .............................................................................. 3

A) General ........................................................................................................................ 3

3. Trouble Shooting ....................................................................................................... 101

4. Flight Compartment Emergency Light Maintenance Practices ................................... 201

4. Tooling ...................................................................................................................... 401

5. Repairs ...................................................................................................................... 801

6. Special Procedures ....................................................................................................... 1

(1) Girt bar and Escape slide floor bracket maintenance practices .................................... 1

(2) Escape slide assembly description /operation and Maintenance practices ................... 1

(3) Additional Notes for the Carriage of Animals other than Horses ................................... 1

(4) Seating Configuration Options ..................................................................................... 2

(5) Required Emergency Equipment for Carriage of Horses or Other Animals .................. 5

(6) Loading layouts - Hoarse and other animal stalls ......................................................... 7

(7) Lead animal handler panel reposition. ....................................................................... 11

(8) Role Change – “CARGO” to “CARRIAGE OF HORSES OR OTHER ANIMALS” .......................................................................................................... 11

(a) General Pallet ................................................................................. 11

(b) In the Cockpit ................................................................................. 13

(c) At the rear Lead Animal Handler seating station ............................. 13

(9) Role Change – “CARRIAGE OF HORSES OR OTHER ANIMALS” to “CARGO” ............................................................................................................ 15

(a) General .......................................................................................... 15

(b) In the Cockpit ................................................................................. 15

(c) In the Main Cargo Compartment ..................................................... 15

(d) Off the Aircraft ................................................................................ 15

Note: In the case of omitted sections they will not appear on this list

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2. Description, Location and Operation

A) General

1) The only permanent line replaceable units/parts introduced by the activation of previously installed design changes are those regarding the emergency egress light (FS1000 at stringer 14R & FS1000 at stringer 14L) and the battery packs for the emergency lighting (at approximately FS747/LBL11.50, FS964/LBL11.50 and FS964/RBL11.50) and Girt bars installed at doorways 2L & 2R refer to special procedures for roll change instructions.

Note: Removal and installation Instructions for those items installed under the

provisioning modification S21.25-13-1665 can be found in document S21.AMMS-0016.

Note: Illustrated parts catalogue for those items installed under the provisioning modification S21.25-13-1665 can be found in document S21.IPCS-0016.

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3. Trouble Shooting Note: The following troubleshooting is provided for quick reference.

(1) In first instance of error message or equipment malfunction check the following:

• Ensure that the Circuit Breakers are closed in accordance with S21.WDMS -

0016

• Perform a reset by complete removal of aircraft power.

• Ensure that connectors/wiring securely terminated in accordance with

S21.WDMS -0016.

• Perform a continuity test of the electrical wiring in accordance with

S21.WDMS -0016.

(2) Egress light trouble shooting

Fault Probable cause Corrective action

Lamp does not illuminate.

1. Defective lamp. 2. Open wiring.

1. Check lamp filament with a digital multimeter. Replace lamp. 2. Check continuity from terminals to lamp holder with a digital multimeter. Replace or repair wiring.

Lamp illuminates

dimly.

1. Corrosion in lamp holder or loose wire connections.

Clean lamp holder and/or terminals and secure electrical connections.

Note: If the issue is not resolved contact STC Twenty One Limited using the Request for

Information/Revision form at the front of this manual.

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4. Flight Compartment Emergency Light Maintenance Practices

(1) EMERGENCY EXIT LIGHTS - MAINTENANCE PRACTICES – LAMP REPLACEMENT (a) Locate the Egress lights installed at the locations FS1000 stringer 14R or

FS1000 stringer 14L.

(b) Follow standard Boeing 747 AMM procedures for the removal of power and grounding of the aircraft.

(c) Pull and collar the EMERGENCY EXIT LIGHTS circuit breaker and attach “DO NOT CLOSE” tag.

(i) Lamp replacement 1. Remove the lens

a. Remove the screws form the lens (and retain for reinstallation)

b. Carefully remove the lens from the fuselage. c. Remove the gasket.

2. Replace the lamp. a. Remove the lamp b. Clean the light assembly clean dry cloth c. Install the new lamp.

3. Close up a. Replace the Gasket. b. Replace lens into the fuselage. c. Reinstall screws removed in step 1. d. resupply electrical power

Figure 201


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(2) EMERGENCY EXIT LIGHTS POWER SUPPLY - MAINTENANCE PRACTICES

(a) This procedure contains these tasks for a power supply for the emergency lights:

• Charge the batteries

• Battery pack replacement

(i) Charge the Batteries 1. References:

• Boeing 737 -400 AMM 24-22-00/201, Manual Control Note: After maintenance and tests of the emergency lights, this task prepares

the emergency lights for a flight of the airplane.

a. Calculate the total time that the emergency lights were on since the last flight of the airplane.

b. Refer to the records that were kept.

Note: Continue this task only if the emergency lights were on for a total of 2 or

more minutes.

c. Supply electrical power (Boeing 737 -400 AMM 24-22-00/201).

Note: The batteries charge automatically when electrical power is supplied to the airplane. It is not necessary to supply electrical power continuously, but the total time must be sufficient to fully charge the batteries.

d. Use this table to calculate the time necessary to charge the

batteries:

TIME THAT THE EMERGENCY LIGHTS

WERE ON

MINIMUM TIME TO SUPPLY ELECTRICAL

POWER

2 Minutes 2 Hours

3 Minutes 3 Hours

4 Minutes 4 Hours

5 Minutes 5 Hours

6 Minutes 6 Hours

7 Minutes 7 Hours

8 Minutes 8 Hours

9 Minutes 9 Hours

10 OR MORE Minutes

16 Hours

e. Remove electrical power if it is not necessary

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(ii) Battery Pack Replacement (Fig. 202)

a. General

Note: Before you install a new battery pack, you can do a test of the power supply with a voltmeter. This is to make sure the power supply will charge the new battery pack.

b. Locations

Approximate locations for the replaceable battery packs are:

• FS747/LBL11.50

• FS964/LBL11.50

• FS964/RBL11.50

c. Referances

• Boeing 737 -400 AMM 20-40-12/201, Electrostatic Discharge Sensitive Devices

• Boeing 737 -400 AMM 24-22-00/201, Manual Control

• Boeing 737 -400 SSM 33-51-00

d. Prepare for the replacement of the battery pack.

i. Open this circuit breaker and attach a D0-NOT-CLOSE tag:

• Load Control Center - Left, P18 EMER EXIT LTS AND PWR

ii. Get access to the power supply (Boeing 737 -400 SSM

33-51-00). Note: For a power supply installed behind a sidewall carpet riser, remove the sidewall carpet riser.

CAUTION: YOU MUST CAREFULLY DO THE STEPS IN THE TASK BELOW TO REMOVE THE BATTERY PACK. A FAILURE TO DO THE STEPS CORRECTLY CAN CAUSE DAMAGE TO THE EQUIPMENT.

iii. Do this task to remove the battery pack: "Electrostatic

Discharge Sensitive Devices" (Boeing 737 -400 AMM 20-40-12/201).

e. Procedure


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(i) Remove the battery pack. 1. Turn the quick-release fasteners counter clockwise.

CAUTION: CAREFULLY REMOVE THE BATTERY PACK FROM ITS POWER SUPPLY. YOU WILL CAUSE DAMAGE TO THE ELECTRICAL CONNECTOR PINS IF THEY ARE NOT CLEAR BEFORE YOU REMOVE THE BATTERY.

2. Carefully move and lift the battery pack away from the power

supply. 3. Install the new battery pack.

a. If it is necessary to know if the power supply can charge the

new batteries, then do this test of the power supply: i. Connect a resistor between the probes of a voltmeter.

NOTE: Use a 22 ohm, 5%, 10 watt resistor. ii. With the voltmeter, make sure there is between 6.27

and 8.66 volts dc between the battery connector pins of the power supply.

b. Make sure the installation date on the instruction tag attached to the battery pack is not an expired date.

Note: Do not remove the instruction tag from the replacement battery pack.

c. Put the replacement battery pack in the power supply assembly.

d. Carefully move the battery pack forward until the pins of the two connectors are fully engaged.

e. Turn the quick-release fasteners clockwise to the detent position.

4. Remove the DO-NOT-CLOSE tag and close this circuit breaker:

• Load Control Center - Left, P18 EMER EXIT LTS AND PWR

5. Do a test of the battery pack.

Note: You can do a test of each battery pack independently or all the battery packs together.

a. To do a test of each battery pack independently, do these

steps: i. Push the test switch on the power supply. ii. Make sure the emergency lights connected to the

battery pack come on (Boeing 737 -400 SSM 33-51-00). iii. Make sure the emergency lights go off automatically

after approximately 1 minute. b. To do a test of all the battery packs together, do these

steps: i. Set the emergency lights switch on the P5 panel to ON.

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ii. Make sure the emergency lights connected to the replacement battery pack are on.

iii. Set the switch to OFF. iv. Make sure the emergency lights are off.

6. Put the airplane back to its usual condition.

a. Close the panels you opened to get access to the power

supplies. b. If the batteries in the replacement battery pack are not fully

charged, supply electrical power for 16 hours. See procedure for power supply for the emergency lights.

Figure 202

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4. Tooling

(1) Unless specified, standard maintenance tooling will be required for the continuing maintenance as described in this manual. If special tooling is required it will be identified within the appropriate section of this supplement maintenance manual.

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5. Repairs

(1) Repair by replacement. Any other repair options must first be approved. Any service failures must be reported to STC Twenty One using the feedback form at the rear of this manual.

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6. Special Procedures

(1) Girt bar and Escape slide floor bracket maintenance practices

a. For Girt bar and Escape slide floor bracket maintenance practices see Boeing AMM 737 -300/-400/-500 25-61-51-201.

(2) Escape slide assembly description /operation and Maintenance practices

b. For Escape slide assembly (door mounted) description /operation and Maintenance practices see Boeing AMM 737 -300/-400/-500 25-61-35.

(3) Additional Notes for the Carriage of Animals other than Horses

a. The animal cage, pen, etc. must conform to IATA LAR standards for the type of animal being carried;

b. The animal cage, pen, etc. conforming to IATA LAR standards must be lashed in accordance with the aircraft cargo loading manual;

c. The combined weight of the animal cage, pen, etc. and pallet must not exceed the maximum bay weight as per the aircraft loading manual;

d. The animal cage, pen, etc. and pallet combined must not reduce STC approved aisle widths (for occupant recovery) or obscure ordinance signs;


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(4) Seating Configuration Options

a. This design change introduces configuration options for seating to the rear of the aircraft.

b. Installation and fitting of the seating pallet consists of three options. See figures 901-903.

Figure 901 Seating configuration 1

LEAD ANIMAL HANDLER POSITION

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Figure 902 Seating configuration 2 (limited to 19 handlers)



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Figure 903 Seating configuration 3 Note: Alt P10 pallets can be 125 x 88 shown are 108 x 88


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(5) Required Emergency Equipment for Carriage of Horses or Other Animals

Figure 904 Required Emergency Equipment Seating Configuration A.

Figure 905 Required Emergency Equipment Seating Configuration B.


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Figure 906 Required Emergency Equipment Seating Configuration C.

Figure 907 Required Emergency Equipment Legend.

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(6) Loading layouts - Horse and other animal stalls

a. Depending on configuration of the seating there are several options for the loading of the animal stalls on the aircraft. See the below Illustrations for the configuration options.


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(7) Lead animal handler panel reposition.

(1) Refer to S21.AMMS-0016 chapter 25-00 section 9

(2) Install applicable placard 11-13-10042-3 or 11-13-10042-4.

(8) Role Change – “CARGO” to “CARRIAGE OF HORSES OR OTHER ANIMALS”

The following instructions are to be carried out prior to the aircraft being released and positioned as available for horse or other animal flights. It is expected that this is carried out by suitably trained personnel.

(a) General Pallet

(3) Check all pallet locks in positions 9, 10 and 11 are operable. NOTE: NO OCCUPANTS MAY BE CARRIED IF ANY PALLET LOCK IS INOPERABLE AT

POSITIONS 9, 10 or 11 as required. (4) Identify seat pallets (full and half) and confirm pallet and seat part numbers

are in accordance with approved configuration drawings above (Figures 901-903).

(5) Check each pallet assembly and seat assembly are certified serviceable. (6) Check each seat bottom position on the two pallets has a portable oxygen

cylinder and nasal mask installed. Check for serviceable condition of each item (cylinder gauge indicates in the green area, mask is undamaged and in sealed bag and hose is clean, not kinked or otherwise damaged).

(7) Check safety equipment stowage is installed onto full seat pallet in accordance

with approved configuration drawings above (Figures 904-907). (8) Check each item of safety equipment (smoke hood, fire extinguishers, 2 off

and torches) is installed and in serviceable condition. Check that Smoke Hood overhaul date and Fire Extinguishers’ weight checks are current.

(9) Check additional portable oxygen equipment stowage is installed onto half

seat pallet in accordance with approved configuration drawings above (Figures 901-903).

(10) Check for serviceable condition of each additional oxygen cylinder, maximum

of ten, (cylinder gauge indicates in the green area, mask is undamaged and in sealed bag and hose is clean, not kinked or otherwise damaged).

(11) Check both rear entrance door escape slides are in position and that the girt

bars are secure in stowage brackets. (12) Check escape slide inflation cylinder is fully charged.


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(13) Check girt bar floor mounted location brackets are clean and in serviceable condition. (See Boeing AMM 737 -00/-400/-500 25-61-51)

(14) Ensure aircraft floor is clean and free from any cargo debris prior to installing

seat pallets. (15) Install seat pallets into the pallet 9 10 or 11 as required positions and secure

using all pallet locks. (16) Install flight interphone headset into communications panel aft of rear right

hand entrance door. (17) Check palletized horse or other animal stalls are serviceable and release

documents are current. (18) Install palletized horses or other animal stalls at approved pallet locations in

accordance with approved configuration drawing. See Special Procedures 4. Loading layouts - Hoarse and other animal stalls (double or triple layout as appropriate).

(19) Install absorbent coco matting (or equivalent) between each installed horses

or other animal stall and ensure no tripping hazard is introduced by installing this material.

(20) Apply power to the aircraft, observing all the aircraft maintenance manual

warnings and cautions, to enable operation of the cabin lighting, placards, passenger address and flight interphone.

(21) Ensure both port and starboard aisle widths are no less than the minimum as

shown in Figure 905.

Figure 905 – Minimum Aisle Widths

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(b) In the Cockpit

(1) Select the role changeover switch from “CARGO” to “CARRIAGE OF HORSES” positions.

(2) Select main cargo compartment lighting switch to “ON” and check all main cabin cargo compartment lights are illuminated.

(3) “NO SMOKING” placards should be “ON” without operation of the switch;

“FASTEN SEAT BELT” placards are controlled by the switch.

(4) Select ordinance placard switches to “OFF.”

(5) Operate cabin pressure Altitude Warning Horn test switch located adjacent to role changeover switch and check that audible warning sounds in main cargo compartment. Release Altitude Warning Horn switch.

(6) Select passenger address on each audio control panel in turn and make test

announcement. Check test announcement is clearly audible at each of the two Animal Handler work stations and at each seat of the Animal Handler seating station.

(7) Set the service interphone ON-OFF switch on the overhead panel, P5, to the

ON position.

(8) Select aft attendant call on flight interphone system. Check call light illuminates on rear right hand communications panel and that a two way communication is established between cockpit and main cargo compartment Lead Animal Handler seating station.

(9) Select emergency lighting switch to “ON.” Check rear main cargo

compartment emergency lights illuminate, external slide slights illuminate and both door exit placard down lights are illuminated. Select “ARMED” at the emergency lights cockpit control panel.

(c) At the rear Lead Animal Handler seating station

(1) Select guarded emergency lighting switch to “ON.” Check rear main cargo compartment emergency lights illuminate, external slides lights illuminate and both door exit placard down lights are illuminated. Select guarded emergency lighting switch to “OFF” and check guard is correctly positioned.

(2) Select cockpit emergency light control panel to “OFF.”

(3) At the communications panel select crew call switch to “CALL”. Check attendant call light illuminates in the cockpit. Release crew call switch.

(4) Switch off all systems still active and remove power from the aircraft.


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(5) Aircraft is now configured for horses or other animal charter flights. If permitted by existing procedures, the configuration change may be recorded in the aircraft technical log.

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(9) Role Change – “CARRIAGE OF HORSES OR OTHER ANIMALS” to “CARGO”

(a) General

(1) Remove absorbent coco matting (or equivalent) from between each installed horse or other animal stall; care is to be exercised as this may now be wetted with urine.

(2) Remove all horse or other animal stall pallets from aircraft.

(3) Remove both seat pallet assemblies from aircraft.

(b) In the Cockpit

(1) Select emergency lighting switch to “OFF.”

(2) Select ordinance placards switches for “FASTEN SEAT BELTS” to “OFF.”

(3) Select the role changeover switch from “CARRIAGE OF HORSES” to “CARGO” positions.

(c) In the Main Cargo Compartment

(1) Inspect cargo compartment floors for any signs of urine contamination and mark areas of any found.

(2) Carry out thorough clean of main cargo compartment floor panels, seat tracks and cargo handling system.

(3) Carry out inspection of the cargo compartment floor areas previously marked for possible urine contamination and clean and renew protective treatments as required and ensure seepage between floor panels and under cargo handling system has not occurred.

(4) Check seat tracks and cargo handling system for signs of corrosion or damage.

(d) Off the Aircraft

(1) Thoroughly clean the inside and outside of each horse or other animal stall pallet with particular care to the corners and crevices where debris and or urine may be trapped.

(2) Check each horse or other animal stall pallet for signs of damage and corrosion and, if none found, return assembly to stores.

(3) Check each item of safety equipment in the stowages or attached to the Animal Handler seats for serviceability, replacing any used items or short lifed items.


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(4) Check each Animal Handler seat for serviceability including condition of seat dress covers.

(5) Check each seat pallet for signs of damage and corrosion.

(6) The seat pallets, seats and items of safety equipment can then be returned to stores.

CARRIAGE OF HORSES OR OTHER ANIMALS

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