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Commercial Airplanes 767 Service Bulletin Number: 767-56A0010 Original Issue: September 07, 2006 Revision 3: March 03, 2011 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment Windows - Number 2 Openable Window - Link Arm Modification Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.

9E991ECCN:

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

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BLANK PAGE

Table of Contents

Revision Transmittal Sheet5

Summary7

1. PLANNING INFORMATION ........................................ 1 1 A. Effectivity ............................................... 1 1

1. Airplanes ............................................ 1 1

2. Spares Affected ........................................ 1 9 B. Concurrent Requirements ...................................... 1 9 C. Reason ................................................ 1 9 D. Description .............................................. 2 0 E. Compliance .............................................. 2 2 F. Approval ............................................... 2 3 G. Manpower .............................................. 2 3 H. Weight and Balance Changes .................................... 2 8 I. Electrical Load Data ......................................... 2 8 J. References .............................................. 2 8

1. Existing Data: ......................................... 2 8

2. Data supplied with this Service Bulletin: ........................... 2 9

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 9 K. Publications Affected ........................................ 2 9 L. Interchangeability and Intermixability of Parts ........................... 3 0

2. MATERIAL INFORMATION ........................................ 3 1 A. Material - Price and Availability ................................... 3 1 B. Industry Support Information .................................... 3 2 C. Parts Necessary For Each Airplane ................................. 3 2

1. Kits/Parts: ........................................... 3 2

2. Parts and Materials Supplied by the Operator: ........................ 3 4

3. Parts Modified and Reidentified: ............................... 3 4

4. Parts Removed and Not Replaced: .............................. 3 6 D. Parts Necessary to Change Spares ................................. 3 6 E. Special Tooling - Price and Availability ............................... 3 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 3 7

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 9 A. GENERAL INFORMATION ..................................... 3 9 B. WORK INSTRUCTIONS ....................................... 4 0 FIGURE 1: NUMBER 2 WINDOW - LINK BRACKET - REMOVAL - LEFT SIDE [Group 1, 4, 6, Configuration 1 ] ................................................ 4 6 FIGURE 2: NUMBER 2 WINDOW - LINK BRACKET - REMOVAL - LEFT SIDE [Group 1, Configuration 2;

Group 2-3; Group 4, Configuration 2; Group 5; Group 6, Configuration 2; Group 7] .... 5 1 FIGURE 3: NUMBER 2 WINDOW - LINK BRACKET - OPTIONAL REWORK - LEFT SIDE [Group 2, 7] . 56 FIGURE 4: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - LEFT SIDE [Group 1, 6, Configuration 1 ] ................................................ 5 8 FIGURE 5: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - LEFT SIDE [Group 1, Configuration 2; Group 2-3; Group 6, Configuration 2; Group 7] ...................... 6 3 FIGURE 6: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - LEFT SIDE [Group 4, Configuration 1 ] ................................................ 6 8

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FIGURE 7: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - LEFT SIDE [Group 4, Configuration 2; Group 5] ........................................... 7 3 FIGURE 8: NUMBER 2 WINDOW - CAM BLOCK - REMOVAL - LEFT SIDE .............. 7 8 FIGURE 9: NUMBER 2 WINDOW - CAM BLOCK - OPTIONAL REWORK - LEFT SIDE ........ 8 1 FIGURE 10: NUMBER 2 WINDOW - CAM BLOCK - INSTALLATION - LEFT SIDE ........... 8 3 FIGURE 11: NUMBER 2 WINDOW - CRANK/ROLLER ASSEMBLY - REMOVAL - LEFT SIDE ..... 8 6 FIGURE 12: NUMBER 2 WINDOW - CRANK/ROLLER ASSEMBLY - OPTIONAL REWORK ...... 8 8 FIGURE 13: NUMBER 2 WINDOW - CRANK/ROLLER ASSEMBLY - OPTIONAL REWORK ...... 9 0 FIGURE 14: NUMBER 2 WINDOW - CRANK/ROLLER ASSEMBLY - INSTALLATION - LEFT SIDE . . 92 FIGURE 15: NUMBER 2 WINDOW - LINK BRACKET - REMOVAL - RIGHT SIDE [Group 1, 4, 6, Configuration 1 ] ................................................ 9 4 FIGURE 16: NUMBER 2 WINDOW - LINK BRACKET - REMOVAL - RIGHT SIDE [Group 1, Configuration 2; Group 2-3; Group 4, Configuration 2; Group 5; Group 6, Configuration 2; Group 7] . . . 99 FIGURE 17: NUMBER 2 WINDOW - LINK BRACKET - OPTIONAL REWORK - RIGHT SIDE [Group 2, 7] ................................................. 1 0 4 FIGURE 18: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - RIGHT SIDE [Group 1, 6, Configuration 1] ........................................ 1 0 6 FIGURE 19: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - RIGHT SIDE [Group 1, Configuration 2; Group 2-3; Group 6, Configuration 2; Group 7] ...................... 1 1 1 FIGURE 20: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - RIGHT SIDE [Group 4, Configuration 1 ] ................................................ 1 1 6 FIGURE 21: NUMBER 2 WINDOW - LINK BRACKET - INSTALLATION - RIGHT SIDE [Group 4, Configuration 2; Group 5] .......................................... 1 2 1 FIGURE 22: NUMBER 2 WINDOW - CAM BLOCK - REMOVAL - RIGHT SIDE ............ 1 2 6 FIGURE 23: NUMBER 2 WINDOW - CAM BLOCK - OPTIONAL REWORK - RIGHT SIDE ...... 1 2 9 FIGURE 24: NUMBER 2 WINDOW - CAM BLOCK - INSTALLATION - RIGHT SIDE .......... 1 3 1 FIGURE 25: NUMBER 2 WINDOW - CRANK/ROLLER ASSEMBLY - REMOVAL - RIGHT SIDE . . . 134 FIGURE 26: NUMBER 2 WINDOW - CRANK/ROLLER ASSEMBLY - INSTALLATION - RIGHT SIDE . 136 FIGURE 27: NUMBER 2 WINDOW - LINK ARM - INSPECTION - LEFT SIDE ............. 1 3 8 FIGURE 28: NUMBER 2 WINDOW - LINK ARM - INSPECTION - RIGHT SIDE ............ 1 4 0

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Original Issue: September 07, 2006 767-56A0010Revision 3: March 03, 2011 4 of 141 BOEING SERVICE BULLETIN 767-56A0010

Commercial Airplanes 767 Service Bulletin Revision Transmittal SheetNumber: 767-56A0010Original Issue: September 07, 2006 Revision 3: March 03, 2011 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment Windows - Number 2 Openable Window - Link Arm Modification This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on airplanes changed as given in Revision 2 of this service bulletin. However, as specified in Revision 1 and Revision 2, more work is necessary on airplanes changed as given in the original issue of this service bulletin. If not previously accomplished, Boeing recommends that operators do an inspection of the number 2 openable window mechanism to make sure that the link arm is in the over-center position, as given in paragraph 1.E., Compliance.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making (NPRM) 2006-NM-224-AD, is related to this service bulletin.

REASON FOR REVISION This revision is sent to delete inspection/modification actions that were previously recommended to be done if a number 2 window assembly is changed or when rigging changes are made.

Changes to this service bulletin include:

— In the Summary Background section and in Paragraph 1.C., Reason: Revised the Background and Reason sections to clarify that accomplishment of this service bulletin will reduce the likelihood (will not ensure) that and unlatched number 2 flight compartment window will open during take off.

— In Paragraph 1.D., Description: Added Revision 3 information and added maintenance zone information.

— In Paragraph 1.E., Compliance: Revised compliance information to remove airplane conditions that were based on line maintenance activities. Also, condensed compliance information into one table due to removal of airplane conditions, which simplified the compliance data.

— In Paragraph 1.K.1., Publications: Added 767 Component Maintenance Manual as an affected publication.

— In Paragraph 2.C.3., Parts Modified and Reidentified: Changed reidentification requirement for 141T4835-47/-48 window assemblies. Clarified note (f).

— In Paragraph 2.E. and paragraph 2.F., Special Tooling information: Revised note (a) to clarify that operators can use their own tool as an alternative to Boeing tool MIT141T4890.

— In Paragraph 3.B., Work Instructions: Deleted variations of the inspection instructions (Parts 2, 3, 6, and 7) that are no longer necessary due to removed conditions and compliance information changes.

— In Paragraph 3. B., Work Instructions: The words "as given in" have been changed to "refer to" throughout the Work Instructions when referencing the Aircraft Maintenance Manual (AMM). Also, PART 4 and PART 8 modification instructions have been revised to separate changes to the airplane and changes to the window assembly.

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— In Paragraph 3.B., Work Instructions: Revised PART 4, step 4 (previously step 16) and PART 8, step 4 (previously step 16) to clarify that fay surface sealing at the cam block is only required on the shim, if a shim is installed.

— In Figure 3: Clarified dimensions for chamfer and clarified note (b) for shot peen requirement.

— In Figures 8 and 22: Deleted note (a) regarding removal of washers. In Revision 1, the intent of note (a) was to give instructions for removal of adjustment washers that may be installed under the cam block. In Revision 2, note (b) was revised to give instructions for removal of adjustment washers. Note (a) should have been deleted in Revision 2.

— In Figures 10 and 24: Deleted note (d) regarding installation of washers. In Revision 1, the intent of note

(d) was to give instructions for installation of adjustment washers under the cam block. In Revision 2, note

(e) was revised to give instructions for installation of adjustment washers. Note (d) should have been deleted in Revision 2.

— In Figure 12: Clarified step 3 and note (d) for location of new hole. Also, added step 9 and notes (e) and (f) for identification of reworked crank/roller assembly.

— In Figure 13: Clarified step 3 and note (c) for location of new hole. Also, added step 8 and notes (d) and (e) for identification of reworked crank/roller assembly.

— In Figures 14 and 26: Deleted note (b) and revised note (c) to refer to Paragraph 2.C.3 for re-identification of the window assembly after modification.

— In Figure 17: Clarified dimensions for chamfer and clarified note (b) for shot peen requirement.

— In Figures 4, 5, 6, 7, 18, 19, 20, 21: Revised note (c) regarding installation of lockwire.

— In Figures 1, 2, 4, 5, 6, 7, 15, 16, 18, 19, 20, and 21: Clarified which steps are not required if MIT141T4890 tool, or equivalent, is used to remove the link bracket. Also, clarified that operators can use their own tool, instead of MIT141T4890, during removal/installation of the link bracket.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY September 07, 2006Original Issue:

January 24, 2008Revision 1:

June 18, 2009Revision 2:

March 03, 2011Revision 3:

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Commercial Airplanes 767 Service Bulletin SummaryNumber: 767-56A0010Original Issue: September 07, 2006 Revision 3: March 03, 2011 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment Windows - Number 2 Openable Window - Link Arm Modification

CONCURRENT REQUIREMENTS None.

BACKGROUND Accomplishment of this service bulletin will reduce the likelihood that a number 2 flight compartment window will open during take off, if the window is not latched. If a number 2 flight compartment window opens during take off, a high speed aborted takeoff or an unscheduled landing will be necessary. In addition, the ability of the flight crew to perform critical take off communication will be adversely affected. Note that proper latching of the number 2 flight compartment windows by the flight crew is required, prior to flight, in order to ensure that a number 2 window will not open during take off.

The modification shown in this service bulletin will allow the number 2 window link arm to be positioned at an angle less than 90 degrees (over-center), in reference to the track roller, when the window is closed.

Boeing has received six reports of the Number 2 windows opening during takeoff roll. This has resulted in aborted takeoffs, which have occurred at speeds up to 140 knots.

The number 2 windows are opened and closed by rotating an operating crank. When closing the window the crank/roller assembly at the end of the torque tube will move and engage the cam block at the top aft corner of the window. On airplanes before line number 930, except line number 923, the crank roller can move at 18 degree increments with one gear tooth rotation. Airplane line number 923 and airplanes after line number 929, have the modification given in this service bulletin installed in production.

Accomplishment of this service bulletin will allow the crank roller to move at 9 degree increments with a change of position of a retaining pin, instead of one gear tooth rotation of 18 degree increments. The link arm that drives the window shut will be positioned at an angle less than 90 degrees (over-center), in reference to the track roller, when the window is closed.

Boeing Service Related Problem (SRP) 767-SRP-56-0012 and 767-SRP-56-0023 are related to this service bulletin.

As a part of a service bulletin validation program, this change was completed on airplane VS078 by the original issue of Service Bulletin 767-56A0010 before the release of Revision 01 of this service bulletin. The change completed on airplane VS078 by the original issue of Service Bulletin 767-56A0010 is equivalent to the release of Revision 01 of this service bulletin. Airplane VS078 has the configuration of a Group 3 airplane.

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ACTION (PRR 12901-58S) INSPECTION: Do a general visual inspection to determine if the link arm on the number 2 window is in an over-center position when the window is closed. If the link arm is not in an over-center position when the window is closed, re-rig the window. If the link arm cannot be rigged to get the over-center position, do the modification as given in this service bulletin.

MODIFICATION: Remove the link brackets from the carriage assembly lower track operating system, left and right. Remove the cam blocks from the window number 2 upper sill, left and right. Remove the crank/roller assembly from the number 2 window assemblies, left and right.

Operators can do one of the two options that follow:

1. Option 1: Replace the link brackets, cam blocks and crank/roller assemblies with new parts. Install the number 2 windows, left and right.

2. Option 2: Rework and replace the cam blocks and crank/roller assemblies. Rework and replace, or install new link brackets. Operators who have older link brackets installed will not be able to rework the link brackets and will need to install new link brackets. Refer to Paragraph 3.B., Work Instructions for reworking existing parts or new part installation applicability.

Group 1-2:

It is recommended that operators accomplish service bulletin 767-56-0002, "WINDOWS - Flight Compartment Windows - Openable Windows Number 2 - Latch Hook and Striker Plate Installation", due to common access.

Group 1, 4, 6:

It is recommended that operators accomplish service bulletin 767-56-0004, "WINDOWS - Number 2 Openable Window- Window Stop Installation", due to common access.

EFFECTIVITY 767-200, -300, -300F and -400ER Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE Refer to Paragraph 1.E., Compliance.

Federal Aviation Administration (FAA) Notice of Proposed Rule Making 2006-NM-224-AD is related to this service bulletin.

INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the configuration changes, inspection and/or repair procedures given in this service bulletin.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Boeing Supplied Kits/Parts.

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Page 9OCROpen in PDF

BOEING SERVICE BULLETIN 767-56A0010 Refer to Paragraph 2.A., Material - Price and Availability.

OPENABLE WINDOW MODIFICATION: NUMBER 2

REWORK OR

INSTALL NEW LATCH

CAM BLOCK LOCK HANDLE MODIFICATION:

REWORK OR

INSTALL NEW

CRANK/ROLLER

ASSEMBLY ' FWD SEE A MODIFICATION:

REWORK OR

INSTALL NEW LINK BRACKET D58609 Original Issue: September 07, 2006 Revision 3: March 03, 2011 767-56A0010

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Page 10OCROpen in PDF

BOEING SERVICE BULLETIN 767-56A0010 CENTER LINE OF LINK ARM REFERENCE LINE (90° FROM

CENTER LINE OF TRACK) INSPECTION:

DO A GENERAL VISUAL

INSPECTION TO DETERMINE IF MINIMUM THE LINK ARM IS IN AN 2 DEGREES WINDOW

OVERCENTER POSITION WHEN THE OVERCENTER ASSEMBLY WINDOW IS CLOSED. IF THE LINK

ARM IS NOT IN AN OVERCENTER

POSITION, RIG THE WINDOW AS

GIVEN IN THE AMM AND IF NECESSARY DO THE MODIFICATION 82-88

AS GIVEN IN THIS SERVICE DEGREES BULLETIN.

LOWER AFT

TRACK LINK ARM

CENTER LINE

OF TRACK INBD

LINK BRACKET

LOOKING OUTBOARD (LEFT SIDE SHOWN, RIGHT SIDE OPPOSITE) 1501063 Original Issue: September 07, 2006 Revision 3: March 03, 2011 767-56A0010

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Commercial Airplanes 767 Service Bulletin Number: 767-56A0010 Original Issue: September 07, 2006 Revision 3: March 03, 2011 ATA System: 5611 SUBJECT: WINDOWS - Flight Compartment Windows - Number 2 Openable Window - Link Arm Modification

1. PLANNING INFORMATION A. Effectivity

1. Airplanes Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-58S for data about this change.

DESCRIPTIONCONFIGURATIONGROUP 767-200 airplane, line numbers 2 through 114 with short grip length bolts installed on the window operating mechanism with common effectivity to Boeing Service Bulletins 767-56-0002 and 767-56-0004.

-1 Group 1 airplanes that HAVE NOT accomplished Boeing Service Bulletin 767-56-0004.

1 Group 1 airplanes that HAVE accomplished Boeing Service Bulletin 767-56-0004.

2 767-200 airplane, line number 1 with short grip length bolts installed on the window operating mechanism and have link brackets that can be reworked installed on the airplane with common effectivity to Boeing Service Bulletin 767-56-0002.

-2 767-200, -300 and -300F airplanes, line numbers 710 through 929 with short grip length bolts installed on the window operating mechanism and have link brackets that can not be reworked installed on the airplane.

-3

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DESCRIPTIONCONFIGURATIONGROUP 767-200 and -300 airplanes, line numbers 213 through 418 with long grip length bolts installed on the window operating mechanism with common effectivity to Boeing Service Bulletin 767-56-0004.

-4 Group 4 airplanes that HAVE NOT accomplished Boeing Service Bulletin 767-56-0004.

1 Group 4 airplanes that HAVE accomplished Boeing Service Bulletin 767-56-0004.

2 767-200 and -300 airplanes, line numbers 419 through 665 with long grip length bolts installed on the window operating mechanism.

-5 767-200 and -300 airplanes, line numbers 115 through 375 with short grip length bolts installed on the window operating mechanism with common effectivity to Boeing Service Bulletin 767-56-0004.

-6 Group 6 airplanes that HAVE NOT accomplished Boeing Service Bulletin 767-56-0004.

1 Group 6 airplanes that HAVE accomplished Boeing Service Bulletin 767-56-0004.

2 767-200, -300, -300F and -400ER airplanes, line numbers 528 through 878 with short grip length bolts installed on the window operating mechanism and have link brackets that can be reworked installed on the airplane.

-7 Airplane Models:

767-200, 767-300, 767-300F, 767-400ER GroupVariable Number 2VA001 1VA002 - VA020 1VA301 - VA315 1VA501 - VA513 6VA514 - VA530 1VA701 - VA712 6VA713 - VA719 1VA801 - VA810 1VB001 - VB002 1VB051 - VB055

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