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BOEING 737

DISPATCH DEVIATIONS
PROCEDURES GUIDE
SUPPLEMENT
CARGO CONVERSION
STC’s
SA2968SO
SA2969SO
SA2970SO
SA2971SO
ST03387AT

P03-0205DD

REVISION 18
1/21/15

INITIAL ISSUE MAY 27, 2003

PEMCO WORLD AIR SERVICES, INC.


TAMPA, FLORIDA USA
B737 DISPATCH DEVIATIONS PROCEDURES GUIDE SUPPLEMENT

LOG OF PAGES INCLUDING REVISIONS

REV. NO. REVISION DATE PAGE NUMBERS

NEW 05/27/2003 Title, ii, iii, iv, 1.21 – 1.0, 1.23 – 1.0,
1.25 – 1.0, 1.25 – 2.0, 1.25 – 2.1, 1.25 – 3.0,
1.26 – 1.0, 1.32 – 1.0, 1.33 – 1.0, 1.33 – 2.0,
1.52 – 1.0, 1.52 – 1.1, 1.52 – 1.2, 1.52 – 2.0,
1.52 – 3.0

1 07/14/2003 Title, ii, 1.25-2.1

2 10/2/2003 Title, ii, iii, 1.25 – 2.1, 1.25 – 3.0, 1.33 – 1.0,
1.33 – 2.0, 1.52 – 1.0, 1.52 – 4.0

3 10/13/2004 Title, ii, 1.25 – 1.0, 1.25-2.0, 1.25-2.1, 1.25-2.2,


1.25-2.3

4 10/15/2004 Title, ii, 1.25 – 1.0, 1.33-2.0

5 11/3/2004 All pages

6 11/18/04 Title, ii, 1.33-2, 1.52-2

7 11/29/04 Title, ii, 1.25-1

8 2/22/06 All

9 5/8/06 Title, ii, 1.21-1, 1-25-1


Deleted 1-25-2 through 1-25-11, 1-32-1,
1.33-1, 1.33-2, 1-52-1

10 6/8/06 Title, ii, iii, 1.52-1, added 1.52-2

11 8/29/06 Title, ii, 1.21, 1.25, 1.26, 1.32, 1.33, 1.52


Realigned item numbering to conform with
MMEL

12 9-7-06 Minor changes in wording to more accurately


agree with MMEL

13 2-23-07 Title, ii, 1.21. Allow dispatch with one pack


inop.

14 5-1-07 Title, ii, 131-1, 33-22, option 1 and 2. Changed


sentence to read - "(M)(O) One caution light
may be illuminated or inoperative provided:" In
Maintenance (M) 1 and 2, changed ref to 33-
36-00 and 52-37-07.

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15 10-3-07 Title, ii, 1.21-1. 21-1, 2), changed sentence to


read main deck cargo compartment instead of
lower cargo compartment.

16 12-19-12 Title, ii, iii, All pages for new logo, Title page
change location, page 1.21 – 1, sect. 21,
corrected a) to 4. For “PACK TURBOFAN” and
page 1.33 – 1, Sect. 33.22. 1) To reflect all
configurations, 737-300 & -400. Removed STC
No. ST01566LA from document.

17 Correct information in section 1.21, AIR


CONDITIONING.
Add step, Repair/ Interval 22 to section 1.21.
Add MAINTENANCE (M) and OPERATION (O)
procedures to section 1.21.

18 1/21/15 Title Page, add STC Numbers.


Page 1.33-1, corrected AMM reference to 52-
37-02.
Page 1.26-1, Corrected the (O) info for the
system.
Page 1.21-4, Add OPERATION (O), 21-4-2 a)
Right Pack Turbofan.

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TABLE OF CONTENTS

ITEM PAGE
LOG OF PAGES INCLUDING REVISIONS ii

TABLE OF CONTENTS iii

DISCUSSION iv

SECTION 1.21
AIR CONDITIONING 1.21- 1
1.21- 2

SECTION 1.25
EQUIPMENT/FURNISHINGS 1.25- 1

SECTION 1.26
FIRE PROTECTION 1.26- 1

SECTION 1.32
LANDING GEAR 1.32- 1

SECTION 1.33
LIGHTS 1.33- 1
1.33- 2
SECTION 1.52
DOORS 1.52- 1
1.52- 2
1.52- 3

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DISCUSSION

This document serves as a supplement to the existing Boeing Dispatch Deviations Procedures Guide
(DDPG) Document No. D6-32545, and is applicable to the Pemco modification of Boeing 737series
aircraft.
The Pemco DDPG Supplement provides the operator(s) with guidelines and procedures required to
operate Pemco modified Boeing 737 aircraft in various nonstandard configurations allowed by applicable
FAA Master Minimum Equipment List (MMEL).
The format of this document will follow the same sequence that appears in the MMEL. Following the
item(s), maintenance and/or operation procedures will be given to assist the operator for dispatching the
aircraft. In the following cases, an item will not be followed by a suggestive procedure:
1. The procedure is obvious.
2. Pemco is not aware of any procedural defects.
3. The MMEL does not require that a procedure be established.
4. The airline operator must supply the procedure, since it depends on operating requirements.
For system definitions and symbols, refer to the FAA MMEL for Boeing 737 aircraft available on URL
http://www.opspecs.com/AFSDATA/MMELs/Final/transport/.

To assist the operator(s) and increase the ease of use of this document, the following is an example of
numbering of the pages of this supplement.

1.25 – 1

PAGE

ATA SYSTEM NUMBER (25 – EQUIPMENT/FURNISHINGS)

PEMCO DDPG SUPPLEMENT SECTION NUMBER

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NUMBER REQUIRED FOR DISPATCH

ITEMS REMARKS OR EXCEPTIONS

21 AIR CONDITIONING
1. Air Conditioning Packs
4) Pemco COMBI (STC C 2 1 Except for ER operations, one may be
ST03387AT), and All inoperative provided only flight deck is
Cargo Configurations occupied.
C 2 1 (O) Except for ER operations, one may be
inoperative provided flight altitude remains at or
below FL 250
C 2 0 (M)(O) Except for ER operations, both may be
inoperative provided:
a) Flight is conducted in an
unpressurized configuration, and
b) Procedures are established and used
to ensure the main deck cargo
compartment remains empty or are
verified to contain only empty cargo
handling equipment, ballast (ballast
may be loaded in ULDs), and/or Fly
Away Kits.
NOTE: Operator MELS must define which
items are approved for inclusion in the Fly
Away Kits.

4. Pack Turbofan C 2 0
2) Combi, QC, and all
Cargo Configurations
a) Right Pack C 1 0 (O) May be inoperative provided right pack is
Turbofan operated only in flight with flaps retracted.
b) Left Pack C 1 0 (O) May be inoperative provided:
Turbofan a) Left pack is operated only in flight with
flaps retracted, and
b) Procedures are established and used
to ensure the main deck cargo
compartment remains empty or is
verified to contain only empty cargo
handling equipment, ballast (ballast
may be loaded in ULDs), and/or Fly
Away Kits.
NOTE: Operator MELS must define which
items are approved for inclusion in the Fly
Away Kits.

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6. Pack Turbofan Valves (-


100/-200/-300/-400/-500)
2) Combi and all Cargo
Configurations (737C,
QC, STCs SA2969SO)
a) Right Pack C 1 0 (M)(O) May be inoperative Closed provided
Turbofan Valve right pack is operated only in flight with flaps
retracted.

b) Left Pack C 1 0 (M)(O) May be inoperative Closed provided:


Turbofan Valve a) Left pack is operated only in flight
with flaps retracted, and
b) Procedures are established and used
to ensure the main deck cargo
compartment remains empty or is
verified to contain only empty cargo
handling equipment, ballast (ballast
may be loaded in ULDs), and/or fly
Away Kits
NOTE: Operator MELS must define which
items are approved for inclusion in
the Fly Away Kits.

22. Forward Outflow Valve C 1 0 Except for 737C and STC ST01566LA and
(-100/-200/-300/-400/-500, ST01961SE cargo or cargo/passenger
Including STC’s operations, may be inoperative closed.
SA2969SO, ST01566LA
and ST01961SE)
C 1 0 May be inoperative open provided both packs
operate normally.
C 1 0 (O) May be inoperative open with one pack
operating normally provided flight altitude
remains at or below FL200.
31. Recirculation Fan(s)
2) (-400 and Pemco -400 C 2 1 One fan may be inoperative provided the left
Combi) pack is operating when OAT is above 100
degrees F (38 degrees C)
5) (-300F/QC, -400F) C 1 0 May be inoperative in cargo configuration
SA2969SO, and
SA2970SO Only)
41. Door Area heater Systems
1) MCD Heating Blankets D 4 0 May be inoperative
(QC Only)

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21-1-4 AIR CONDITIONING PACKS

MAINTENANCE (M)
Manually position the outflow valve in the full open position.
1. Position the Pressurization Mode selector to AC MAN or DC MAN.
2. Hold the VALVE toggle switch in the OPEN position until valve position indicator indicates full open.
OPERATION (O)
1. Limit altitude to 10,000 ft. for passenger flights.
2. Non-passenger flights above 10,000 ft. require flight crew to be on oxygen.
3. Except for ditching, keep the outflow valve in the full open position.
4. Limit climb and decent rates to 500 FPM to avoid passenger discomfort.
5. Position the ISOLATION VALVE switch to CLOSED after starting engines.
6. To improve passenger cabin and crew compartment temperatures:

A. If possible, pre-condition the cabin to a low temperature prior to dispatch. A low initial cabin
temperature will result in a lower peak temperature.
B. Maintain the highest allowable flight altitude.
C. Minimize cabin heat by pulling the shades down and turning off unnecessary lights.

For 737 Cargo:


D. Position GASPER FAN switch to ON.

For 737 QC and Combi:


E. Position RECIRC FAN switch(es) to AUTO.
F. Estimated stabilized temperatures at the end of 30 minutes of flight are shown in this table:

NOTE 1: Prolonged operation at TAT below 0 degrees C (32 F) can cause freezing of
unheated water systems located in the aft lower lobe.

NOTE 2: Operation at TAT above 32 degrees C (90 F) is not recommended due to the
resulting high temperature in the passenger and crew cabins.

TAT No. of Passenger Cabin Crew Cabin Temperature


Degrees C Passengers Temperature
Deg. F Deg. C Deg. F Deg. C
-1 0 45 7 70 21
-1 100 75 24 75 24
10 0 65 18 85 29
10 100 85 29 95 35
21 0 85 29 100 38
21 100 95 35 105 40
32 0 105 40 120 49
32 100 105 40 120 49

7. Operators must establish and use procedures to verify the main deck cargo compartment remains
empty or containers only ballast, empty cargo handling equipment (ballast may be loaded in UDLs or
fly away kits.

NOTE: The operator’s MEL must define which items are approved for inclusion in the fly away kits
and which can be used as ballast.

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21-4-2 a) RIGHT PACK TURBOFAN

OPERATION (O)
8. Do these steps when flaps are extended

A. Position R PACK switch to OFF.


B. Position the ISOLATION VALVE switch to CLOSED.

For 737 Cargo:


9. When dispatching with one operating pack supplied by engine bleed air on takeoff, determine takeoff
performance based on packs ON.

For 737 QC and Combi:


10. When dispatching with one operating pack supplied by engine bleed air on takeoff:

A. Determine V1 (MCG) based on engine bleed for packs OFF.


B. Determine takeoff performance based on packs AUTO.

21-4-2 b) LEFT PACK TURBOFAN

OPERATION (O)
11. Do these steps when flaps are extended

A. Position L PACK switch to OFF.


B. Position the ISOLATION VALVE switch to CLOSED.

For 737 Cargo:


12. When dispatching with one operating pack supplied by engine bleed air on takeoff, determine takeoff
performance based on packs ON.

For 737 QC and Combi:


13. When dispatching with one operating pack supplied by engine bleed air on takeoff:

A. Determine V1 (MCG) based on engine bleed for packs OFF.


B. Determine takeoff performance based on packs AUTO

14. Operators must establish and use procedures to verify the main deck cargo compartment remains
empty or containers only ballast, empty cargo handling equipment (ballast may be loaded in UDLs or
fly away kits.

NOTE: The operator’s MEL must define which items are approved for inclusion in the fly away kits
and which can be used as ballast.

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21-22-0 FORWARD OUTFLOW VALVE

OPERATION (O)
1. If both packs are operative, outflow valve may be open or closed with no altitude restriction.
1. If one pack is inoperative and the outflow valve is inoperative open, limit airplane altitude to FL290 or
below.
2. When increased air flow is necessary with the flaps extended (takeoff and landing), use the APU to
supply bleed air to the operating pack.
A. Right pack inoperative:
1) Do the Supplementary Procedure – Air Systems “No Engine Bleed Takeoff and Landing”
(Refer to the Boeing Flight Crew Operations Manual)

NOTE: Keep the PACK switch to OFF and the ISOLATION VALVE switch to CLOSE.
B. Left pack inoperative – PRIOR to takeoff or landing:
1) Engine No. 1 BLEED air switch to OFF.
2) R PACK switch to AUTO.
3) L PACK switch to OFF.
4) ISOLATION VALVE switch to OPEN.
5) Engine No, 2 BLEED air switch to OFF.
6) APU BLEED air switch to ON.
C. Left pack inoperative – AFTER takeoff or landing:
1) APU BLEED air switch to ON.
2) Engine No. 2 BLEED air switch to ON.
3) ISOLATION VALVE switch to CLOSE.
4) Engine No. 1 BLEED air switch to ON.

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25 EQUIPMENT /
FURNISHINGS
5) Cargo Compartment
Restraint Components
1) Passenger Pallets C - - (M) One lock per pallet may be inoperative
(737-300 QC) provided:
a) Three seats in the group associated
with the lock are blocked by folding
and securing backrests in a forward
position, and
b) If more than one lock is inoperative,
the pallet must be removed.
NOTE: If a pallet lock cover is broken or
missing, the associated lock is
considered inoperative.
2) Cargo Pallet Locks C - - (M)(O) Restraints may be inoperative or
(Pemco 737F/QC and missing provided:
Combi) a) Cargo loading limits defined in Pemco
Weight and Balance Manual
Supplement are observed.
b) Inoperative restraints do not impede
loading
MAINTENANCE (M)
1. If passenger pallet has a single broken lock, block three seats in the group associated with lock by
folding and securing the backrests in a forward position. If more than one lock is is inoperative,
remove the seat pallet.
2. If cargo restraints are inoperative, verify that inoperative restraints do not impede loading. If
inoperative restraint interferes with loading, remove restraint.
OPERATION (O)
1. Refer to applicable Pemco Weight and Balance Supplement for loading limits.

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26 FIRE PROTECTION

14. Main Deck Cargo C - 0 (O)May be inoperative provided procedures are


Compartment Fire established and used to ensure the main
Detection/Suppression deck cargo compartment remains empty, or
Systems is verified to contain only empty cargo
handling equipment, ballast (ballast may be
loaded in ULDs), and/or Fly Away Kits.
NOTE: Operator MELs must define which items
are approved for inclusion in the Fly
Away Kits, and which materials can be
used as ballast.
3) Smoke Detectors

(-300F/QC) C 10 5 Each zone must have at least one detector


operational in cargo mode.
(-300QC only) C 10 0 May be inoperative when aircraft is in
passenger mode.
a) System Test C 1 0 (M)May be inoperative provided an acceptable
Feature (-300 only) method is used to verify detector system
integrity.
b) System Power C 1 0 (M) May be inoperative provided smoke
(Blue) Light detectors operate normally.
(PEMCO Aeroplex,
Inc) (-300QC, -
300F, STC
SA2970SO)

MAINTENANCE (M)
1. If the system test feature is inoperative, confirm system operation by introducing smoke from a
smoke generator into the sensing port. Placard Test Switch “Test Inoperative”, or “Main Cabin
Smoke Detector Station Inoperative”.
2. Advise the crew that the system has been tested.
NOTE: The Detection System is activated when power is applied to the airplane and the cargo smoke
detector circuit breaker is closed, and power switch is placed to the ON position.
OPERATION (O)
1. Define items approved for inclusion in Fly Away Kits and materials to be used as ballast in Operator
MEL.

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32 LANDING GEAR

6. Landing Gear Warning and


Indicating Systems (-100/-
200/-300/-400/-500)

1) Secondary Gear B 1 0 (O) May be inoperative provided:


Warning System, a) Main Gear and Nose Gear Viewers are
Pemco F/QC and accessible during all phases of flight.
Combi

OPERATION (O)
1. If Secondary Gear Warning System is inoperative, ensure existing floor sight ports for main landing
gear down and locked are accessible during all phases of flight.

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33 LIGHTS

21. Main Deck Cargo Door C 2 0 (M) May be inoperative for night operations
Floodlights (-300 and -400) provided alternate procedures are
established and used.
C 2 0 May be inoperative for day operations.
NOTE: Not required for all passenger
operations.
22. Main Deck Cargo Door –
System Annunciator
Lights (Pemco Aeroplex)

1) System Annunciator A 2 1 (M)(O) One warning light may be illuminated or


Lights, Pilot’s inoperative provided:
Overhead Panel a) Alternate procedures are
(737-300, -400) established and used to verify main
cargo door is closed and locked,
and
b) Repairs are made within two flight
days.
2) System Annunciator A - - (M)(O) One caution light may be illuminated or
Lights, Operator inoperative provided:
Control Panel a) It is not VENT DOOR OPEN light
(Pemco Aeroplex, b) Vent door handle is locked
Inc. -300 and -400) c) Outside view port is verified green,
d) Individual lock is not loose (Latch
and Lock system Locks are spring
loaded), and
e) Main cargo door is verified closed,
latched and locked.
f) Repairs are made within two flight
days.
MAINTENANCE (M)
1. For removal/installation procedures for cargo door floodlights, refer to Pemco Maintenance Manual
(33-36-00).
2. Verify adjustment of switch associated with inoperative or illuminated light. (Pemco Maintenance
Manual Supplement 52-37-02)
OPERATIONS (O)
1. Check that associated system indicator light on the pilot’s overhead panel is operating normally.
2. Verify by depressing annunciator PUSH-TO-TEST switch that lights are illuminated on the operator’s
panel if the door is open, not latched, not locked and/or vent door open.

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3. Check through the view ports located on the Main Cargo Door (MCD) carpet riser that the forward
and aft locks are properly engaged.
4. Check through the brush located between the seat pallet and the MCD beneath the carpet riser, that
all latches are properly engaged.

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ITEMS REMARKS OR EXCEPTIONS

52 DOORS
10. Main Cabin Cargo Door
(PEMCO Aeroplex, Inc. STC
SA2969SO)
1) Latch Pin, Latch A 8 7 (M)(O) One may be broken or missing from
Base and Lower the main cargo door provided:
Jamb Latch Fitting a) A visual check is made before
departure to ensure no defects
are visible on other latch bases,
pins or lower jamb latch fittings,
b) Latch pin and latch base of
damaged latch does not interfere
with continuous safety operation
of remaining latches and pins,
c) Flight is conducted in
unpressurized configuration,
d) Procedures are established and
used to ensure the main and
lower lobe cargo compartments
remain empty, or are verified to
contain only empty cargo
handling equipment, ballast
(ballast may be loaded in ULDs),
and/or Fly Away Kits.
e) Repairs are made within 2 flight
days.
NOTE: Operator MELs must define which
items are approved for inclusion in
the Fly Away Kits, and which
materials can be used as ballast.
2) Hydraulic Cylinder B 2 1 (M) One may be inoperative provided
Latching Mechanism remaining latch cylinder is operative
through the gear box.
C 2 0 (M) May be inoperative provided the door
may be latched and unlatched
manually.
3) Hydraulic System B 1 0 (M) May be inoperative provided the door
Control Valve may be locked and unlocked manually.
4) Lifting Actuator B 2 0 (M) May be inoperative provided door is
Assembly verified latched and locked.
5) Double Piloted Check B 1 0 (M) May be inoperative provided the door
Valve may be locked and unlocked manually.

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6) Lock, Lock Mount A 2 1 (M)(O) One may be inoperative provided:


and Locking Fittings
a) No defects are visible on
remaining lock or lock mount of
associated door.
7) Sequence Valves B 2 0 (M) May be inoperative provided door is
verified latched and locked.
8) Priority Valve B 1 0 (M) May be inoperative provided door is
verified latched and locked.
9) Hydraulic Unlock C 2 0 (M) May be inoperative provided door can
Actuators be unlocked and unlatched manually.
11. Main Cargo Door – C 1 0 (M) May be inoperative provided Main
Electrically Power Cargo Door is verified Closed, Latched, and
Hydraulic Pump Locked before each departure
(Standalone Hydraulic
System Only)
12. Main Cargo Door – C 1 0 (M) May be inoperative.
Hydraulic Hand Pump
(737F/QC and Combi)
13. Main Cargo Door Lift
Systems
1) Electric and /or C 1 0 One may be inoperative provided the
Manual Mode remaining mode operates normally
(-200C, -400 All
(M) May be inoperative provided the door is
Cargo and -400
verified closed and locked before each
COMBI)
departure.

MAINTENANCE (M)
1. If leakage is detected in the MCD Hydraulic System, use manual valves to isolate cargo door
hydraulic system. Lock wire isolation valves closed and verify that leakage has stopped. Placard
main cargo door control panel - “INOP”.
2. Remove broken lock, lock mount, or locking fitting that interferes with door operation.
3. Verify that latch mechanism functions properly with remaining latch cylinder.
4. Verify door can be latched and locked, and unlocked and unlatched manually.
5. Verify Main Cargo Door is Latched and Locked.
6. For removal of Main Cargo Door Hydraulic Hand Pump refer to PEMCO Maintenance Manual
Supplement (refer to PEMCO Maintenance Manual Supplement 52-39-16).
7. For removal of Main Cargo Door Hydraulic Pump (For Stand-a-Lone Hydraulic System only refer to
PEMCO Maintenance Manual Supplement 52-38-17).
P03-0205DD Page 1.52 – 2
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OPERATIONS (O)
1. Verify main Cargo Compartment contains only empty ULDs. Aft ULDs may contain ballast and/or Fly-
a-way kit to ensure CG is within flight limits.
2. Aft Lower lobe cargo compartment may contain ballast and/or Fly-a-way kit to ensure CG is within
flight limits.
3. Define materials used as ballast and items approved for inclusion in the Fly Away Kits in Operator
MELs.

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