# Boeing Special Attention Service Bulletin 757-30-0019: U.S. DOT/FAA - SB-757-30-0019-03

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- Title as filed: U.S. DOT/FAA - SB-757-30-0019-03
- Pages: 56
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## Text

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### Page 1

Commercial 
Airplanes
757
Service Bulletin
SPECIAL ATTENTION
Number: 757-30-0019
Original Issue: July 19, 2006
Revision 3: December 16, 2011
ATA System: 3041 5611
SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield
Inspection and Replacement
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Unpublished Work - All Rights Reserved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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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
1. PLANNING INFORMATION ........................................ 1 1
A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 4
B. Concurrent Requirements ...................................... 1 4
C. Reason ................................................ 1 5
D. Description .............................................. 1 6
E. Compliance .............................................. 1 6
F. Approval ............................................... 2 0
G. Manpower .............................................. 2 0
H. Weight and Balance Changes .................................... 2 1
I. Electrical Load Data ......................................... 2 2
J. References .............................................. 2 2
1. Existing Data: ......................................... 2 2
2. Data supplied with this Service Bulletin: ........................... 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 2 2
K. Publications Affected ........................................ 2 2
L. Interchangeability and Intermixability of Parts ........................... 2 3
2. MATERIAL INFORMATION ........................................ 2 5
A. Material - Price and Availability ................................... 2 5
B. Industry Support Information .................................... 2 5
C. Parts Necessary For Each Airplane ................................. 2 5
1. Kits/Parts: ........................................... 2 5
2. Parts and Materials Supplied by the Operator: ........................ 2 7
3. Parts Modified and Reidentified: ............................... 2 8
4. Parts Removed and Not Replaced: .............................. 2 8
D. Parts Necessary to Change Spares ................................. 2 8
E. Special Tooling - Price and Availability ............................... 2 8
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 3 1
A. GENERAL INFORMATION ..................................... 3 1
B. WORK INSTRUCTIONS ....................................... 3 2
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD ......................... 3 5
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD ........................ 4 1
FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD ................... 4 7
FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 49
FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD ........ 5 1
FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD ................... 5 2
FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . 54
FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD ....... 5 6
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Commercial 
Airplanes
757
Service Bulletin
SPECIAL ATTENTION
Revision Transmittal SheetNumber: 757-30-0019Original Issue: July 19, 2006
Revision 3: December 16, 2011
ATA System: 3041 5611
SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield
Inspection and Replacement
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 is related to this service bulletin.
More work is necessary on the airplanes inspected in accordance with the original issue or Revision 1 of this
service bulletin.
No more work is necessary on the airplanes inspected in accordance with Revision 2 of this service bulletin.
No more work is necessary on the airplanes that have done the terminating action in accordance with the original
issue or Revision 1 or Revision 2 of this service bulletin.
REASON FOR REVISION
This revision is sent to add Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 and
change the text in the Compliance Table.
Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph
3.A., General Information - Notes.
These sections were changed:
1. In Summary and Paragraph 1.E., Compliance, added FAA AD 2010-15-01.
2. In Paragraph 1.D., Description, added terminating action statement.
3. In Paragraph 1.E., Compliance, changed the text in the Compliance Table.
4. In Paragraph 1.F., Approval, added Alternative Method Of Compliance (AMOC) paragraph.
5. In Paragraph 1.J.1, Existing Data, added FAA AD 2010-15-01 and a changed a Standard Wiring Practices
Manual (SWPM) reference.
6. In Paragraph 2.A., Material - Price and Availability, updated kit price and availability.
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7. In Paragraph 2.C.1., Kit/Parts, added new windshield part numbers and serial numbers to the kit table.
8. In Paragraph 2.E., Special Tooling - Price and Availability, updated tool kit price.
9. In FIGURE 1 and FIGURE 2:
a. Removed circle notes 6 and 7 and changed the illustrations.
b. Step tables, changed the format and steps in the tables.
c. Footnotes, added AMM reference.
10. In FIGURE 4 and FIGURE 7, flagnote tables, changed a SWPM reference.
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
July 19, 2006Original Issue:
December 19, 2007Revision 1:
April 19, 2010Revision 2:
December 16, 2011Revision 3:
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Commercial 
Airplanes
757
Service Bulletin
SPECIAL ATTENTION
SummaryNumber: 757-30-0019Original Issue: July 19, 2006
Revision 3: December 16, 2011
ATA System: 3041 5611
SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield
Inspection and Replacement
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS
None
BACKGROUND
This service bulletin gives instructions to do a detailed inspection of the electrical connections on the left and
the right windshields. Instructions are also given to replace the windshields and make changes to their related
wire bundles. A new windshield design is available that uses a different electrical connection.
Boeing received nine reports from eight operators of electrical arcs at the terminal blocks of the flight compartment
windows. More than one of these reports included data to show that the results of the arcs were open flame
incidents. One operator found an indication of damage at a terminal and tightened a loose connection. The
terminal had internal damage that could not be seen. Less than six months after the connection was tightened
there was a report from the operator of an open flame incident on the same windshield.
The electrical connections on the windows are made with lugs that are attached with screws. The windshield is
the number 1 window in the flight compartment. All of the windows in the flight compartment are electrically
heated. The windshield gets a much larger electrical load.
An investigation found that the cause of the electrical arcs is loose terminal connections. A loose connection
increases the heat at the terminal which can cause damage to the internal solder joint. Damaged solder joints
are the primary cause for the electrical arcs. The primary causes of loose connections are the incorrect torque
of the screw or an incorrectly installed screw.
The detailed inspection given in this service bulletin is to look for damage or a loose electrical connection on
the windshield. If there are indications of electrical arcs or damage to the electrical connection, the windshield
is replaced. If there is a loose electrical connection, the correct torque is applied to tighten it. If a connection
cannot be tightened to the correct torque, the windshield is replaced. When a windshield with an electrical
connection that uses pins and sockets is installed, the related wire bundle on the airplane is changed.
When the changes given in this bulletin are done, the windshields will have better electrical connections. The
new connections are made with pins and sockets. The pin and socket connections will prevent the risk of electrical
arcs as a result of loose connections.
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Boeing Service Related Problems (SRP) 757-SRP-30-0031 and 757-SRP-56-0015 are related to this service
bulletin.
As a part of a service bulletin validation program, this change was completed on airplane NB141 by Service
Bulletin 757-30-0019 Validation Copy 1 before the initial release of this service bulletin. The change completed
on airplane NB141 by Service Bulletin 757-30-0019 Validation Copy 1 is equivalent to the initial release of this
service bulletin. Airplane NB141 has the configuration of a Group 1 airplane.
ACTION (PRR 54530-265S)
In the flight compartment, do a detailed inspection of the J1, J4 and J5 terminals on the left and the right
windshields. Replace windshields that use screws and lugs for the electrical connections with a windshield that
uses pins and sockets for the electrical connections. Cut the bulb seal to give clearance for terminals on the
new windshield. Change the related wire bundle.
EFFECTIVITY
All 757-200, -200CB, and -200PF Airplanes except NA001. Refer to Paragraph 1.A.1., Airplanes for the list of
affected airplanes.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 is related to this service bulletin.
See Service Bulletin Paragraph 1.E. for compliance information.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
MANPOWER
Elapsed HoursTotal Task HoursWork Package
1.51.5Work Package 1 - Detailed Inspection of the Left
Windshield
1.51.5Work Package 2 - Detailed Inspection of the Right
Windshield
4.758.5Work Package 3 - Left Windshield Replacement and
Wiring Change
4.758.5Work Package 4 - Right Windshield Replacement and
Wiring Change
MATERIAL INFORMATION
Boeing Supplied Kits/Parts
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 757-30-0019
WORK PACKAGE 4:
CUT THE BULB SEAL AND
REPLACE THE RIGHT WINDSHIELD.
CHANGE THE RELATED WIRING.
WORK PACKAGE 2:
INSPECT THE RIGHT WINDSHIELD
WORK PACKAGE 3:
CUT THE BULB SEAL AND
REPLACE THE LEFT WINDSHIELD.
CHANGE THE RELATED WIRING.
WORK PACKAGE 1:  482078
INSPECT THE LEFT WINDSHIELD
Original Issue: July 19, 2006
Revision 3: December 16, 2011  BOEING PROPRIETARY -  757-30-0019
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Commercial 
Airplanes
757
Service Bulletin
SPECIAL ATTENTION
Number: 757-30-0019
Original Issue: July 19, 2006
Revision 3: December 16, 2011
ATA System: 3041 5611
SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield
Inspection and Replacement
BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
Refer to Service Bulletin Index Document D624N001 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 54530-265S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP
Airplanes with windshields that use screw and lug electrical
connections. The location of the circuit breaker for window heat is in
a different location than for Group 2.
-1
Airplanes with windshields that use screw and lug electrical
connections. The location of the circuit breaker for window heat is in
a different location than for Group 1.
-2
Airplane Models:
757-200, 757-200CB, 757-200PF
GroupVariable Number
1NA002 - NA028
1NA191 - NA199
1NA201 - NA239
1NA301 - NA305
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GroupVariable Number
1NA341 - NA352
1NA391 - NA399
1NA401 - NA408
1NA441 - NA447
1NA501 - NA586
1NB001 - NB004
1NB021 - NB023
1NB036 - NB041
1NB051 - NB053
1NB061 - NB073
1NB079
1NB131 - NB148
1NB161 - NB162
1NB166 - NB168
1NB201 - NB204
1NB221 - NB228
1NB230
1NB236
1NB239
1NB261 - NB267
1NB291 - NB299
1NB301 - NB302
1NB311 - NB312
1NB321 - NB331
1NB421 - NB438
1NB446
1NB451 - NB454
1NB501 - NB523
1NB561
1NB571
1NB581 - NB583
1NC001 - NC033
1NC041 - NC042
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GroupVariable Number
1NC051 - NC052
1NC056 - NC062
1NC066 - NC084
1NC091 - NC094
1NC151
1NC161
2NC901 - NC951
2NC971 - NC974
1ND001 - ND007
1ND011 - ND059
1ND111 - ND113
1ND161 - ND199
1ND201 - ND203
1ND221 - ND225
1ND241 - ND248
1ND301 - ND322
1ND401
1ND891
1ND895
1NE001 - NE008
1NE011 - NE088
1NE091 - NE094
1NE141 - NE150
1NE161 - NE177
1NE201 - NE204
1NE301 - NE302
1NE311 - NE325
1NJ001 - NJ004
1NJ031 - NJ032
1NJ551 - NJ555
1NN001 - NN002
1NN051 - NN052
1NP901 - NP904
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GroupVariable Number
2NS601 - NS616
1NT001 - NT009
1NT201 - NT202
1NT231 - NT234
1NT237 - NT240
1NT242
1NT245 - NT248
1NT281 - NT289
1NT341 - NT347
1NT351 - NT360
1NT371 - NT373
1NT375 - NT379
1NT381 - NT386
1NT401 - NT409
1NT411 - NT412
1NT426 - NT427
1NT431 - NT432
1NT436 - NT438
1NT441 - NT442
1NT446
1NT701 - NT769
1NT791 - NT796
1NT861 - NT862
1NT881 - NT885
1NT901 - NT916
1NT971 - NT985
1NU031 - NU038
2. Spares Affected
Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts
Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for
the recommended use.
B. Concurrent Requirements
None
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C. Reason
This service bulletin gives instructions to do a detailed inspection of the electrical connections on the
left and the right windshields. Instructions are also given to replace the windshields and make changes
to their related wire bundles. A new windshield design is available that uses a different electrical
connection.
Boeing received nine reports from eight operators of electrical arcs at the terminal blocks of the flight
compartment windows. More than one of these reports included data to show that the results of the
arcs were open flame incidents. One operator found an indication of damage at a terminal and tightened
a loose connection. The terminal had internal damage that could not be seen. Less than six months
after the connection was tightened there was a report from the operator of an open flame incident on
the same windshield.
The electrical connections on the windows are made with lugs that are attached with screws. The
windshield is the number 1 window in the flight compartment. All of the windows in the flight compartment
are electrically heated. The windshield gets a much larger electrical load.
An investigation found that the cause of the electrical arcs is loose terminal connections. A loose
connection increases the heat at the terminal which can cause damage to the internal solder joint.
Damaged solder joints are the primary cause for the electrical arcs. The primary causes of loose
connections are the incorrect torque of the screw or an incorrectly installed screw.
The detailed inspection given in this service bulletin is to look for damage or a loose electrical connection
on the windshield. If there are indications of electrical arcs or damage to the electrical connection, the
windshield is replaced. If there is a loose electrical connection, the correct torque is applied to tighten
it. If a connection cannot be tightened to the correct torque, the windshield is replaced. When a windshield
with an electrical connection that uses pins and sockets is installed, the related wire bundle on the
airplane is changed.
When the changes given in this bulletin are done, the windshields will have better electrical connections.
The new connections are made with pins and sockets. The pin and socket connections will prevent
the risk of electrical arcs as a result of loose connections.
Boeing Service Related Problems (SRP) 757-SRP-30-0031 and 757-SRP-56-0015 are related to this
service bulletin.
As a part of a service bulletin validation program, this change was completed on airplane NB141 by
Service Bulletin 757-30-0019 Validation Copy 1 before the initial release of this service bulletin. The
change completed on airplane NB141 by Service Bulletin 757-30-0019 Validation Copy 1 is equivalent
to the initial release of this service bulletin. Airplane NB141 has the configuration of a Group 1 airplane.
Revision 1 was sent to change the No.1 Windshield Assembly part numbers supplied in the Top Kits.
Revision 2 was sent to tell operators that have not done the terminating action in the compliance of
this service bulletin will now need to also inspect the J1 and J4 windshield lugs and terminals.
Revision 3 is sent to add Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01
and change the text in the Compliance Table.
Terminology has been changed in the Work Instructions to agree with the terminology defined in
Paragraph 3.A., General Information - Notes.
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D. Description
In the flight compartment, do a detailed inspection of the J1, J4 and J5 lugs and terminals on the left
and the right windshields. Replace windshields that use screws and lugs for the electrical connections
with a windshield that uses pins and sockets for the electrical connections. Cut the bulb seal to give
clearance for terminals on the new windshield. Change the related wire bundle.
The changes in this service bulletin will not change the Engine Indication and Crew Alerting System
(EICAS).
Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this
service bulletin.
Revision 2 - More work is necessary on airplanes changed as shown in the original issue and Revision
1 of this service bulletin.
Revision 3 - More work is necessary on the airplanes inspected in accordance with the original issue
or Revision 1 of this service bulletin.
No more work is necessary on airplanes inspected in accordance with Revision 2 of this service bulletin.
No more work is necessary on airplanes that have done the terminating action in accordance with the
original issue or Revision 1 or Revision 2 of this service bulletin
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1:
Affected Maintenance Zones
ZoneModel
211, 212757-200, 757-200CB, 757-
200PF
Group 2:
Affected Maintenance Zones
ZoneModel
211, 212757-200PF
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 is related to this service
bulletin.
Boeing recommends that the inspection given in this service bulletin be done within 500 flight hours or
150 days after the effective date of AD 2010-15-01 .
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Compliance Table:
Repeat Interval
(Whichever Occurs
Later)
Compliance Time
(Whichever Occurs First)
ActionCondition
Terminating action for
this bulletin.
----Replace with windshield that
uses pins and sockets for win-
dow heat power connection in
accordance with Accomplish-
ment Instructions Work Pack-
ages 3 and 4.
Windshield that uses
screws and lugs for win-
dow heat power connec-
tion.
Every 6000 flight
hours or 24 months
until windshield is re-
placed with windshield
that uses pins and
sockets for the win-
dow heat power con-
nection in accordance
with Accomplishment
Instructions Work
Packages 3 and 4.
Within 500 flight hours or 150
days, after the effective date
of AD 2010-15-01.
Do the actions that follow for
J1, J4 and J5 window heat
power connections:
1. Inspect the shipside wiring
and terminal lug (including
cover), look for signs of melted
or discolored insulation.
2. Inspect the window terminal
blocks, look for signs of melt-
ing, distortion or cracking.
3. Inspect the window heat
power connection for evidence
of cross threading by making
sure the terminal lug is parallel
with the window terminal
block.
PPG Windshield that us-
es screws and lugs for
window heat power con-
nection.
4. Inspect the terminal lug for
looseness.
5. Address the inspection
findings as described in Inspec-
tion Conditions 1 thru 4.
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Compliance Table:
Repeat Interval
(Whichever Occurs
Later)
Compliance Time
(Whichever Occurs First)
ActionCondition
Every 12,000 flight
hours or 48 months
until windshield is re-
placed with windshield
that uses pins and
sockets for window
heat power connection
in accordance with
Accomplishment In-
structions Work Pack-
ages 3 and 4.
Within 500 flight hours or 150
days, after the effective date
of AD 2010-15-01.
Do the actions that follow for
J1, J4 and J5 window heat
power connections:
1. Inspect the shipside wiring
and terminal lug (including
cover), look for signs of melted
or discolored insulation.
2. Inspect the window terminal
blocks, look for signs of melt-
ing, distortion or cracking.
3. Inspect the window heat
power connection for evidence
of cross threading by making
sure the terminal lug is parallel
with the window terminal
block.
GKN Windshield that us-
es screws and lugs for
window heat power con-
nection.
4. Inspect the terminal lug for
looseness.
5. Address the inspection
findings as described in Inspec-
tion Conditions 1 thru 4.
----Before further flight.1. Repair or replace shipside
wiring as necessary. Refer to
Standard Wiring Practices
Manual SWPM 20-10-13 as
an accepted procedure.
Inspection Condition 1 -
If the inspection reveals
one or more signs of the
following:
1. Melted shipside wire
insulation. 2. If the terminal lug has melt-
ed, replace the shipside termi-
nal lug and windshield in accor-
dance with Work Package 1,
step 2, or Work Package 2,
step 2; as applicable.
2. Discolored shipside
wire insulation.
3. Melted terminal lug.
4. Melted cover.
----Before further flight.1. Replace windshield in accor-
dance with Work Package 1,
step 2 or Work Package 2,
step 2; as applicable.
Inspection Condition 2 -
If the inspection reveals
one or more signs of the
following:
1. Melted window termi-
nal block.
2. Distorted or cracked
window terminal block.
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Compliance Table:
Repeat Interval
(Whichever Occurs
Later)
Compliance Time
(Whichever Occurs First)
ActionCondition
----Before further flight.1. Inspect the terminal for
looseness. If the cross thread-
ed terminal is loose: torque the
terminal screw to 25-30 in-lb.
Inspection Condition 3 -
If the inspection reveals
evidence the window
heat power connection is
cross threaded. 2. Re-inspect terminal lug for
looseness.
3. If terminal lug is still loose
replace windshield in accor-
dance with Work Package 1,
step 2, or Work Package 2,
step 2; as applicable.
----Within 150 days or 500 flight
hours after the inspection.
4. If terminal lug is tight, re-
place windshield in accor-
dance with Work Package 1,
step 2, or Work Package 2,
step 2; as applicable.
----Before further flight.1. Torque the terminal screw
to 25-30 in-lb.
Inspection Condition 4 -
If the inspection reveals
the terminal lug is loose. 2. Re-inspect terminal lug for
looseness.
3. If terminal lug is still loose
then disassemble, inspect and
reassemble the electrical con-
nection in accordance with
Work Package 1, step 2 or
Work Package 2, step 2; as
applicable.
----Within 150 days or 500 flight
hours, after the reassembly
of the windshield heat power
connection. (a)
Do a detailed inspection in ac-
cordance with Work Package
1, step 2 or Work Package 2,
step 2; as applicable.
Window heat power con-
nection is reassembled
(on windshields that uses
screws and lugs for win-
dow heat power connec-
tion).
OR
If the windshield is re-
placed with same type
windshield that uses
screws and lugs for win-
dow heat power connec-
tion.
(a) The initial inspection after installing a new window or a new terminal screw is to verify that the window
heat power connection is correctly made. An improperly installed screw (under torqued or cross threaded)
can be identified regardless of the time since installation. If a screw is properly installed and torqued, there
is no evidence that it will loosen over time. The inspection steps outlined in this service bulletin should be
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Compliance Table:
Repeat Interval
(Whichever Occurs
Later)
Compliance Time
(Whichever Occurs First)
ActionCondition
followed. Refer to either condition "Window heat power connection is reassembled" or "windshield is re-
placed with same type windshield" in the Compliance Table for inspection requirements.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved, as well as European
Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved
airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on
the airplane in its original Boeing delivery configuration or as modified by other approved Boeing
changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection
or modification) defined in this service bulletin as an alternative method of compliance to the requirements
of paragraphs (f), (g), (h) and (i) of AD 2010-15-01. All provisions of AD 2010-15-01 that are not
specifically referenced in the above statement remain fully applicable and must be complied with.
G. Manpower
The table below shows an estimate of the task-hours necessary to do this inspection or change one
window for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust
the estimate with operator task-hour data if necessary. The estimate does not include lost time. These
are some examples of lost time:
— Time to adjust to the workplace
— Time to schedule the work
— Time to examine the work
— Time to cure the materials
— Time to make the parts
— Time to find the tools.
Work Package 1 - Inspection of the Left Windshield
Elapsed HoursTask-HoursNumber of Per-
sons
Task
1.501.501FIGURE 1
1.501.50Total per Windshield
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Work Package 2 - Inspection of the Right Windshield
Elapsed HoursTask-HoursNumber of Per-
sons
Task
1.501.501FIGURE 2
1.501.50Total per Windshield
Work Package 3 - Replacement of the Left Windshield and Changes to the Related Wiring
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.501.02Access
1.252.52Remove the Left Windshield
0.250.251FIGURE 3 - Cut the Bulb Seal
0.500.501FIGURE 4 and FIGURE 5 -
Change the Wiring
1.53.02Install the Left Windshield
0.250.251Tests
0.501.02Close
4.758.5Total per Windshield
Work Package 4 - Replacement of the Right Windshield and Changes to the Related Wiring
Elapsed HoursTask-HoursNumber of Per-
sons
Task
0.501.02Access
1.252.52Remove the Right Windshield
0.250.251FIGURE 6 - Cut the Bulb Seal
0.500.501FIGURE 7 and FIGURE 8 -
Change the Wiring
1.53.02Install the Right Windshield
0.250.251Tests
0.501.02Close
4.758.5Total per Windshield
H. Weight and Balance Changes
None
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I. Electrical Load Data
Not changed
J. References
1. Existing Data:
a. Engineering Change Memo PRR 54530-265S
b. Boeing Service Related Problem (SRP) 757-SRP-30-0031, 757-SRP-56-0015
c. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2010-15-01
d. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-10
e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-13, 20-10-18, 20-10-19,
20-20-00, 20-30-11, 20-64-16, 20-64-18
f. 757 Aircraft Maintenance Manual (AMM) 30-41-00, 56-11-01
g. Wiring Diagram 30-41-11, 30-41-12
h. Boeing Service Bulletin 767-56-0012
2. Data supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
None
K. Publications Affected
1. Publications
Chapter-SectionPublication
30-41, 56-11757 Maintenance Manual
30-41757 Wiring Diagram Manual
56-11757 Illustrated Parts Catalog
2. Damage Tolerance Based Structural Inspections:
Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue
Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the
Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary.
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L. Interchangeability and Intermixability of Parts
Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability
information.
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### Page 25

2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators
are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the Revision 03
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
Revision 03 date
of this Service
Bulletin (Calendar
Days)
NameKit Number
$19,687.00130Top Kit - Left Windshield - PPG with hy-
drophobic coating
012N8926-7
$19,687.00130Top Kit - Right Windshield - PPG with hy-
drophobic coating
012N8926-8
B. Industry Support Information
Boeing warranty remedies are not available for the configuration changes given in this service bulletin.
C. Parts Necessary For Each Airplane
1. Kits/Parts:
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: Two top kits (one for the left side and one for the right side) and the items shown in
Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each
airplane.
Kit 012N8926
NotesNameQTYNew Part Number
-7-8
Top Kit - Left Windshield, PPG
with Hydrophobic coating
-.012N8926-7
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Kit 012N8926
NotesNameQTYNew Part Number
-7-8
Top Kit - Right Windshield, PPG
with Hydrophobic coating
.-012N8926-8
(a) (b) (c) (d)
(f) (h) (j) (l)
(m)
PPG Left Windshield Assembly
with Hydrophobic coating
1.141W7400-43
(a) (b) (c) (e)
(g) (i) (k) (l)
(m)
PPG Right Windshield Assembly
with Hydrophobic coating
.1141W7400-44
Wire Kit - Flight Deck Window
Heat
1.280N3355-1
Wire Kit - Flight Deck Window
Heat
.1280N3355-2
(a) Keep the existing part if there are other uses for it.
(b) This part is not used in production.
(c) You cannot use the existing part to replace the new or changed part.
(d) As an option operators can install Left Windshield part number 141T4801-59.
(e) As an option operators can install Right Windshield part number 141T4801-60.
(f) As an option operators can install Left Windshield part number 141W7400-31 or
141W7400-33 with serial numbers 04001Hxxxx thru 05365Hxxxx or with serial numbers
04001Rxxxx thru 05365Rxxxx.
(g) As an option operators can install Right Windshield part number 141W7400-32 or
141W7400-34 with serial numbers 04001Hxxxx thru 05365Hxxxx or with serial numbers
04001Rxxxx thru 05365Rxxxx.
(h) As an option operators can install Left Windshield part number 141W7400-37 or
141W7400-39 with serial numbers 06001Hxxxx thru 06338Hxxxx or with serial numbers
06001Rxxxx thru 06338Rxxxx.
(i) As an option operators can install Right Windshield part number 141W7400-38 or
141W7400-40 with serial numbers 06001Hxxxx thru 06338Hxxxx or with serial numbers
06001Rxxxx thru 06338Rxxxx.
(j) As an option operators can install Left Windshield part number 141W7400-35 or
141W7400-41.
(k) As an option operators can install Right Windshield part number 141W7400-36 or
141W7400-42.
(l) PPG Aerospace - Transparencies Div Glass (V53117) P.O. Box 2200 1719 U.S. Highway
72 East Huntsville, AL 35811-9660
(m) Serial numbers with letter H or R are acceptable. Serial numbers with letter H, are new
parts for Boeing production/spares. Serial numbers with letter R are parts rebuilt by
PPG.
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Kit 280N3355
NotesNameQTYNew Part Number
-1-2-101-102
Wire Kit - Flight Deck
Window Heat
-...280N3355-1
Wire Kit - Flight Deck
Window Heat
.-..280N3355-2
Kit, Wire Bundle
W2304
1.-.280N3355-101
Kit, Wire BundleW2314.1.-280N3355-102
BMS 13-52 Expandable
Sleeve
..1.280N3355-10103
BMS 13-52 Expandable
Sleeve
...1280N3355-10203
(a)Wire Identified W2304-
0001-12
..1.-
(b)Wire Identified W2304-
0002-12
..1.-
(a)Wire Identified W2314-
0001-12
...1-
(b)Wire Identified W2314-
0002-12
...1-
(c)Terminal Lug..33BACT12AC-12
(c)Socket Contact..33M39029/57-359
(a) BMS 13-60, Type 1, Class 1, AWG 12, length 66 inches
(b) BMS 13-60, Type 1, Class 1, AWG 12, length 33 inches
(c) There are more parts than are necessary.
2. Parts and Materials Supplied by the Operator:
NotesNameQTYPart Number /
Specification
(a) (b) (c)Lacing Tape, Red10 feetBMS 13-54
(a) (b) (d)Lacing Tape, Green10 feetBMS 13-54
(a) Type 3, Class 1
(b) Gudebrod Incorporated (V82110) Griffith Towers PO Box 357 Pottstown,
PA 19464
(c) BACS38K5C, red Tie Strap is optional. See the Qualified Products List at
the end of the Boeing Material Specification (BMS) for the supplier data.
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NotesNameQTYPart Number /
Specification
(d) BACS38K5F, green Tie Strap is optional. See the Qualified Products List
at the end of the Boeing Material Specification (BMS) for the supplier data.
3. Parts Modified and Reidentified:
The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the
number of parts changed on each airplane.
NotesNew Part NumberNameQTYExisting Part
Number
(a) (b)-Glareshield1233N8300-( )
(a) Make the change given in this service bulletin.
(b) There is no equivalent Boeing part number for the changed part. Identify
on the part that the change given in this service bulletin was made.
4. Parts Removed and Not Replaced:
None
D. Parts Necessary to Change Spares
None
E. Special Tooling - Price and Availability
Boeing can supply the tool(s) shown in Paragraph 2.F., Special Tooling Necessary to do this Service
Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of
the service bulletin. The tool(s) are subject to the terms and conditions of the Boeing standard purchase
order acknowledgement. Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin number and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or Boeing Part Page
2. Fax to (206) 662-7145
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REFER TO THE BOEING PART PAGE ON MY BOEING FLEET.COM OR CONTACT FIRST
RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT)
AND PRICE INFORMATION
Purchase Data:
Unit Price as of
the Revision 03
date of this Ser-
vice Bulletin (US
Dollars)
NameTool Kit Number
$766.00Windshield Handling SlingA56001-2 (part of
Sling Set A56001-
15)
F. Special Tooling Necessary to do this Service Bulletin
To get the tools shown below, refer to Paragraph 2.E., Special Tooling - Price and Availability.
Maintenance and overhaul tools in the manuals shown in Paragraph 1.J., References, can also be
necessary. Examine operator tool supply to make sure all necessary tools are available.
NameTool Kit Number
Windshield Handling SlingA56001-2 (part of
Sling Set A56001-15)
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### Page 31

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL
PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,
METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE
DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR
OTHER ELECTRICAL DAMAGE.
NOTE: 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for
definition of the acronyms.
2. Obey all of the warnings and cautions given in the specified manual sections.
3. The work instructions are divided into work packages. Task Hours and Elapsed Hours
for each package are given in Paragraph 1.G., Manpower. You can do each work
package independently.
4. Unless shown differently, these dimensions and tolerances are used:
– Linear dimensions are in inches
– Hole dimensions for standard solid rivets and fasteners are in Structural Repair
Manual (SRM) Chapter 51
5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures,
and SWPM 20-10-19 for the wire separation requirements, as accepted procedures.
6. A Detailed Inspection is defined as: An intensive examination of a specific item,
installation, or assembly to detect damage, failure, or irregularity. Available lighting
is normally supplemented with a direct source of good lighting at an intensity deemed
appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be
necessary. Surface cleaning and elaborate procedures may be required.
7. These work instructions refer to procedures included in other Boeing documents.
When the words "refer to" are used and the operator has an accepted alternative
procedure, the accepted alternative procedure can be used. When the words "in
accordance with" are included in the instruction, the procedure in the Boeing document
must be used.
8. If it is necessary to remove more parts for access, you can remove those parts. If
you can get access without removing identified parts, it is not necessary to remove
all of the identified parts. Jacking and shoring limitations must be observed.
9. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
The removed part can be discarded if a new or serviceable part is installed.
10. This service bulletin includes functional test procedures for the systems changed by
this service bulletin. More functional tests can possibly be necessary in accordance
with standard maintenance practices because of interruption to other airplane systems.
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B. WORK INSTRUCTIONS
WORK PACKAGE 1 - INSPECTION OF THE LEFT WINDSHIELD
WARNING: BEFORE YOU DO MAINTENANCE ON THE WINDSHIELD HEAT SYSTEM, OPEN THE
CIRCUIT BREAKER GIVEN IN THE STEP THAT FOLLOWS. IF THIS CIRCUIT BREAKER
IS NOT OPEN, YOU CAN GET AN ELECTRICAL SHOCK WHEN YOU TOUCH THE
TERMINAL.
1. Open the circuit breaker shown below and attach a DO-NOT-CLOSE tag to it:
Circuit BreakerNameLocation Panel /
Position
Airplane
Group
C391WINDOW HEATER 1LP70 / C131
C391WINDOW HEATER 1LP31 / A052
2. Do a detailed inspection of the left windshield and any corrective actions if necessary, in accordance
with FIGURE 1.
3. Remove the DO-NOT-CLOSE tag and close the circuit breaker shown below:
Circuit BreakerNameLocation Panel /
Position
Airplane
Group
C391WINDOW HEATER 1LP70 / C131
C391WINDOW HEATER 1LP31 / A052
WORK PACKAGE 2 - INSPECTION OF THE RIGHT WINDSHIELD
WARNING: BEFORE YOU DO MAINTENANCE ON THE WINDSHIELD HEAT SYSTEM, OPEN THE
CIRCUIT BREAKER GIVEN IN THE STEP THAT FOLLOWS. IF THIS CIRCUIT BREAKER
IS NOT OPEN, YOU CAN GET AN ELECTRICAL SHOCK WHEN YOU TOUCH THE
TERMINAL.
1. Open the applicable circuit breaker shown below and attach a DO-NOT-CLOSE tag to it:
Circuit BreakerNameLocation Panel /
Position
C392WINDOW HEATER 1RP37 / J2
2. Do a detailed inspection of the right windshield and any corrective actions if necessary, in
accordance with FIGURE 2.
3. Remove the DO-NOT-CLOSE tag and close the circuit breaker shown below:
Circuit BreakerNameLocation Panel /
Position
C392WINDOW HEATER 1RP37 / J2
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WORK PACKAGE 3 - REPLACEMENT OF THE LEFT WINDSHIELD AND CHANGES TO THE
RELATED WIRE BUNDLE
WARNING: THE WINDOW HEAT SYSTEM MUST BE DISARMED WHEN YOU REMOVE THE
WINDOWS. IF THE WINDOW POWER IS ON, YOU CAN GET AN ELECTRICAL SHOCK
WHEN YOU TOUCH THE WINDOW. THE SHOCK CAN CAUSE INJURY TO PERSONS.
1. Open this circuit breaker and attach a DO-NOT-CLOSE tag to it:
Circuit BreakerNameLocation Panel /
Position
Airplane
Group
C391WINDOW HEATER 1LP70 / C131
C391WINDOW HEATER 1LP31 / A052
2. Remove the left windshield. Use the windshield handling sling, A56001-2. Refer to 757 AMM
56-11-01 as an accepted procedure.
3. Cut the bulb seal for the left windshield in accordance with FIGURE 3.
4. Change the wiring for the window heat on the left windshield in accordance with FIGURE 4 and
FIGURE 5.
5. Install the left windshield. Use the windshield handling sling, A56001-2. Refer to 757 AMM 56-11-01
as an accepted procedure. At the operator's choice, use one of the windshields shown below:
Part of Top KitPart NumberDescription
012N8926-7141W7400-43PPG with Hydrophobic Coating
6. Remove the DO-NOT-CLOSE tag and close this circuit breaker:
Circuit BreakerNameLocation Panel /
Position
Airplane
Group
C391WINDOW HEATER 1LP70 / C131
C391WINDOW HEATER 1LP31 / A052
7. Do the test "Operational Test - Flight Compartment Window Anti-Icing System". Refer to 757 AMM
30-41-00 as an accepted procedure.
8. Put the airplane in a serviceable condition.
WORK PACKAGE 4 - REPLACEMENT OF THE RIGHT WINDSHIELD AND CHANGES TO THE
RELATED WIRE BUNDLE
WARNING: THE WINDOW HEAT SYSTEM MUST BE DISARMED WHEN YOU REMOVE THE
WINDOWS. IF THE WINDOW POWER IS ON, YOU CAN GET AN ELECTRICAL SHOCK
WHEN YOU TOUCH THE WINDOW. THE SHOCK CAN CAUSE INJURY TO PERSONS.
1. Open this circuit breaker and attach a DO-NOT-CLOSE tag to it:
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Circuit BreakerNameLocation Panel /
Position
C392WINDOW HEATER 1RP37 / J2
2. Remove the right windshield. Use the windshield handling sling, A56001-2. Refer to 757 AMM
56-11-01 as an accepted procedure.
3. Cut the bulb seal for the right windshield in accordance with FIGURE 6.
4. Change the window heat wiring for the right windshield in accordance with FIGURE 7 and FIGURE
8.
5. Install the right windshield. Use the windshield handling sling, A56001-2. Refer to 757 AMM
56-11-01 as an accepted procedure. At the operator's choice, use one of the windshields shown
below:
Part of Top KitPart NumberDescription
012N8926-8141W7400-44PPG with Hydrophobic Coating
6. Remove the DO-NOT-CLOSE tag and close this circuit breaker:
Circuit BreakerNameLocation Panel /
Position
C392WINDOW HEATER 1RP37 / J2
7. Do the test "Operational Test - Flight Compartment Window Anti-Icing System". Refer to 757 AMM
30-41-00 as an accepted procedure.
8. Put the airplane in a serviceable condition.
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BOEING SERVICE BULLETIN 757-30-0019
3 SCREW
3) SCREW
TERMINAL
BLOCK,
TERMINAL  LUG,
LUG  W2304  BLOCK,  LUG  WIRING
LUG,
WIRING
TERMINAL
BLOCK,
LUG,
WIRING  ) SCREW
J5
@ LUG
INBD
TB5028  " FWD  482068
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD
(SHEET 1 OF 6)
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### Page 36 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
LUG
(WB0710
LUG  TO TERMINAL  LUG PARALLEL  SHOWN)  TO TERMINAL  LUG NOT PARALLEL
(WB0710
SHOWN)
TERMINAL  TERMINAL
ACCEPTABLE  NOT ACCEPTABLE
LUG PARALLEL TO TERMINAL  LUG NOT PARALLEL TO TERMINAL
WALLACE AND BLACK LUG
LUG PARALLEL TO  LUG NOT PARALLEL
TERMINAL AND  LUG  TO TERMINAL AND
O-RING EVENLY  / (CWCO1-1210  O-RING NOT EVENLY  LUG
COMPRESSED  SHOWN)  COMPRESSED  / (CWC01-1210
SHOWN)
TERMINAL  TERMINAL
ACCEPTABLE  NOT ACCEPTABLE
LUG PARALLEL TO TERMINAL  LUG NOT PARALLEL TO TERMINAL
CORY / TRI-STAR LUG
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD
(SHEET 2 OF 6)
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### Page 37 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
135-
COVER
34G SCREW
LUG
LOCKWASHER
TERMINAL
WALLACE AND BLACK LUG
235
COVER
345) SCREW
LUG
LOCKWASHER
4)5
O-RING
TERMINAL
CORY / TRI-STAR LUG  1698037
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD
(SHEET 3 OF 6)
Original Issue: July 19, 2006
Revision 3 December 16, 2011  BOEING PROPRIETARY -  757-30-0019
Copyright © Unpublished Work - See page 1 for details.  37 of 56

### Page 38

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
at the J1, J4 and J5
connection. (a)
3J1, J4, J5Terminal BlockInspect1
(b)3-LugInspect
(c)3WIRE BUNDLE W2304WiringInspect
3-CoverRemove / Keep2
to make sure it is a
tight connection. (d)
(e) (f) (g)
3-LugInspect
not necessary if the
lug is loose. (h)
3-CoverInstall (Kept)
CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A
DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.
to 25 to 30 inch
pounds of torque.
Refer to SWPM 20-
64-16 as an accept-
ed procedure. (i) (j)
3-ScrewTorque3
to make sure the
connection is tight.
3-LugInspect
not necessary if the
lug cannot be tight-
ened.
3-CoverInstall (Kept)
to make sure the
screw is installed
and there is no dam-
age to terminal, lug
or screw.
3-ScrewRemove4
3-WasherRemove
3-O-ringRemove
to make sure the
terminal or lug is not
damaged. (k)
3J1, J4, J5TerminalInspect
(l)3-LugInspect
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD
(SHEET 4 OF 6)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
38 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 39

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A
DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.
to make sure lug is
assembled to termi-
nal with new, undam-
aged and correct
hardware. (m) (n)
3-ScrewInstall (New)5
3-WasherInstall (New)
(o)3-O-ringInstall (New)
to 25 to 30 inch
pounds of torque.
Refer to SWPM 20-
64-16 as an accept-
ed procedure. (p)
3-ScrewTorque
3-CoverInstall (Kept)
(a) If the terminal block has melted, distorted or cracked, replace the windshield; refer to 757 AMM 56-11-01
as an accepted procedure.
(b) If the terminal lug or cover has melted, replace the shipside terminal lug, refer to SWPM 20-64-16; and
replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure.
(c) If the shipside wire insulation is melted or discolored, then repair or replace shipside wiring as necessary.
Refer to Standard Wiring Practices Manual SWPM 20-10-13 as an accepted procedure.
(d) If the terminal lug moves while applying light manual pressure to the strain-relief on the lug, then the screw
that attaches it must be tightened. There are four causes for a loose terminal. 1-The screw is not tightened
to the correct torque. 2-The terminal is damaged. 3-The incorrect screw is installed. The correct screw
part number is given in SWPM 20-64-16. 4-The screw is cross threaded.
(e) If the lug is not parallel with the terminal, then the screw is cross threaded. Check for lug alignment, the
lug and terminal must be viewed from the side. It may be necessary to view the lug and terminal from the
exterior side of the window.
(f) If the lug shows signs of arcing, blueing, overheating or melting, replace the lug, refer to SWPM 20-64-
16; and replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure.
(g) If the lug is installed correctly, is tight, and is parallel to the terminal block install the cover. No more work
is necessary.
(h) If the lug is loose, do step 3.
(i) The screw is only tightened if the lug is loose. If it is the correct screw and it cannot be tightened to 25 to
30 inch pounds, do steps 4 and 5.
(j) If the cross threaded screw can not be tightened, replace the window. Refer to 757 AMM 56-11-01 as an
accepted procedure.
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD
(SHEET 5 OF 6)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
39 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 40

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(k) If the terminal block mating surface has contamination, clean surface. Refer to SWPM 20-20-00 Cleaning
Method 5 as an accepted procedure. If the terminal shows signs of arcing, blueing, overheating, pitting
corrosion, or other surface damage, the window must be replaced. Refer to 757 AMM 56-11-01 as an
accepted procedure.
(l) If the mating surface on the terminal lug has contamination, clean surface. Refer to SWPM 20-20-00
Cleaning Method 5 as an accepted procedure. If the lug cannot be cleaned or shows signs of arcing,
blueing, overheating, pitting corrosion, or other surface damage, the lug must be replaced. Refer to SWPM
20-64-16 as an accepted procedure.
(m) Reassemble the lug to the terminal with a new screw, lock washer and o-ring. Make sure the o-ring is in-
stalled prior to assemble of the lug to the terminal. Refer to SWPM 20-64-16 as an accepted procedure.
(n) Make sure the screw has been aligned correctly.
(o) A new o-ring is only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 for the correct screw,
washer and o-ring.
(p) Do step 2 to make sure the screw has been installed correctly and is a tight connection.
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD
(SHEET 6 OF 6)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
40 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 41 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
) SCREW
LUG
LUG
TERMINAL  W2314  TERMINAL
BLOCK,  BLOCK,
WIRING  LUG,  WIRING  LUG,
I SCREW
TERMINAL
BLOCK,
LUG,
WIRING
) LUG
INBD <
FWD ‹  482071
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD
(SHEET 1 OF 6)
Original Issue: July 19, 2006
Revision 3 December 16, 2011  757-30-0019
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  41 of 56

### Page 42 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
LUG
(WB0710
LUG  LUG PARALLEL  TO TERMINAL  SHOWN)  TO TERMINAL  LUG NOT PARALLEL
(WB0710
SHOWN)
TERMINAL  TERMINAL
ACCEPTABLE  NOT ACCEPTABLE
LUG PARALLEL TO TERMINAL  LUG NOT PARALLEL TO TERMINAL
WALLACE AND BLACK LUG
LUG PARALLEL TO  LUG NOT PARALLEL
TERMINAL AND  LUG  TO TERMINAL AND
O-RING EVENLY  / (CWCO1-1210  O-RING NOT EVENLY  LUG
COMPRESSED  SHOWN)  COMPRESSED  / (CWC01-1210
SHOWN)
TERMINAL  TERMINAL
ACCEPTABLE  NOT ACCEPTABLE
LUG PARALLEL TO TERMINAL  LUG NOT PARALLEL TO TERMINAL
CORY / TRI-STAR LUG
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD
(SHEET 2 OF 6)
Original Issue: July 19, 2006
Revision 3 December 16, 2011  BOEING PROPRIETARY -  757-30-0019
Copyright © Unpublished Work - See page 1 for details.  42 of 56

### Page 43 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
236
COVER
345 SCREW
LUG
LOCKWASHER
14)
TERMINAL
WALLACE AND BLACK LUG
13€
COVER
3X4X5) SCREW
LUG
(1)2
LOCKWASHER
O-RING
1) 4)
TERMINAL
CORY / TRI-STAR LUG
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD
(SHEET 3 OF 6)
Original Issue: July 19, 2006
Revision 3 December 16, 2011  757-30-0019
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  43 of 56

### Page 44

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
at the J1, J4 and J5
connection. (a)
3J1, J4, J5Terminal BlockInspect1
(b)3-LugInspect
(c)3WIRE BUNDLE W2314WiringInspect
3-CoverRemove / Keep2
to make sure it is a
tight connection. (d)
(e) (f) (g)
3-LugInspect
not necessary if the
lug is loose. (h)
3-CoverInstall (Kept)
CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A
DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.
to 25 to 30 inch
pounds of torque.
Refer to SWPM 20-
64-16 as an accept-
ed procedure. (i) (j)
3-ScrewTorque3
to make sure the
connection is tight.
3-LugInspect
not necessary if the
lug cannot be tight-
ened.
3-CoverInstall (Kept)
to make sure the
screw is installed
and there is no dam-
age to terminal, lug
or screw.
3-ScrewRemove4
3-WasherRemove
3-O-ringRemove
to make sure the
terminal or lug is not
damaged. (k)
3J1, J4, J5TerminalInspect
(l)3-LugInspect
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD
(SHEET 4 OF 6)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
44 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 45

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A
DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.
to make sure lug is
assembled to termi-
nal with new, undam-
aged and correct
hardware. (m) (n)
3-ScrewInstall (New)5
3-WasherInstall (New)
(o)3-O-ringInstall (New)
to 25 to 30 inch
pounds of torque.
Refer to SWPM 20-
64-16 as an accept-
ed procedure. (p)
3-ScrewTorque
3-CoverInstall (Kept)
(a) If the terminal block has melted, distorted or cracked, replace the windshield; refer to 757 AMM 56-11-01
as an accepted procedure.
(b) If the terminal lug or cover has melted, replace the shipside terminal lug, refer to SWPM 20-64-16; and
replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure.
(c) If the shipside wire insulation is melted or discolored, then repair or replace shipside wiring as necessary.
Refer to Standard Wiring Practices Manual SWPM 20-10-13 as an accepted procedure.
(d) If the terminal lug moves while applying light manual pressure to the strain-relief on the lug, then the screw
that attaches it must be tightened. There are four causes for a loose terminal. 1-The screw is not tightened
to the correct torque. 2-The terminal is damaged. 3-The incorrect screw is installed. The correct screw
part number is given in SWPM 20-64-16. 4-The screw is cross threaded.
(e) If the lug is not parallel with the terminal, then the screw is cross threaded. Check for lug alignment, the
lug and terminal must be viewed from the side. It may be necessary to view the lug and terminal from the
exterior side of the window.
(f) If the lug shows signs of arcing, blueing, overheating or melting, replace the lug, refer to SWPM 20-64-
16; and replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure.
(g) If the lug is installed correctly, is tight, and is parallel to the terminal block install the cover. No more work
is necessary.
(h) If the lug is loose, do step 3.
(i) The screw is only tightened if the lug is loose. If it is the correct screw and it cannot be tightened to 25 to
30 inch pounds, do steps 4 and 5.
(j) If the cross threaded screw can not be tightened, replace the window. Refer to 757 AMM 56-11-01 as an
accepted procedure.
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD
(SHEET 5 OF 6)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
45 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 46

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(k) If the terminal block mating surface has contamination, clean surface. Refer to SWPM 20-20-00 Cleaning
Method 5 as an accepted procedure. If the terminal shows signs of arcing, blueing, overheating, pitting
corrosion, or other surface damage, the window must be replaced. Refer to 757 AMM 56-11-01 as an
accepted procedure.
(l) If the mating surface on the terminal lug has contamination, clean surface. Refer to SWPM 20-20-00
Cleaning Method 5 as an accepted procedure. If the lug cannot be cleaned or shows signs of arcing,
blueing, overheating, pitting corrosion, or other surface damage, the lug must be replaced. Refer to SWPM
20-64-16 as an accepted procedure.
(m) Reassemble the lug to the terminal with a new screw, lock washer and o-ring. Make sure the o-ring is in-
stalled prior to assemble of the lug to the terminal. Refer to SWPM 20-64-16 as an accepted procedure.
(n) Make sure the screw has been aligned correctly.
(o) A new o-ring is only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 for the correct screw,
washer and o-ring.
(p) Do step 2 to make sure the screw has been installed correctly and is a tight connection.
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD
(SHEET 6 OF 6)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
46 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 47

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY
numbers shown below are the number of parts necessary for this figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
CAUTION: DO NOT CUT THE STRUCTURE BELOW THE BULB SEAL. THE WINDOW SILL IS A HIGH
MOISTURE AREA AND MOISTURE CAN CAUSE CORROSION IF THE FINISH IS DAMAGED.
DAMAGE TO THE FINISH MUST BE REPAIRED.
to clear the new ter-
minal. (a)
-233T8300-7Bulb SealCut1
(b)--GlareshieldIdentify2
FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD
(SHEET 1 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
47 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 48

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(a) If the finish below the bulb seal is damaged, it will need to be sealed with chemical treatment and primer.
Refer to SOPM 20-41-02 and SOPM 20-43-03 as accepted procedures.
(b) Part Mark with service bulletin number before new windshield is installed. Refer to SOPM 20-50-10 as
an accepted procedure.
FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
48 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 49 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
W2304
+ A-AA +
D3322
+ A-AB +
D3324
- A-AC -
D3326
TB5028
STA 225  B35 LEFT WINDOW 1
WL 225
LBL 37
- 0001-12  =1
- 0002-12
J5
B35 LEFT WINDOW 1
REFERENCE: WIRING DIAGRAM 30-41-11
- ADDED WIRE OR NEW ROUTING
FAT DELETED WIRE OR FORMER ROUTING
482073
FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD
(SHEET 1 OF 2)
Original Issue: July 19, 2006
Revision 3 December 16, 2011  757-30-0019
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  49 of 56

### Page 50

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMEFLAG
NOTE
1BMS 13-60, Type 1,
Class 1, AWG 12
Wire1
1BMS 13-60, Type 1,
Class 1, AWG 12
Wire2
or optional BACS38K5C Tie Strap.
Red is for left channel separation.
Refer to Standard Wiring Practices
Manual SWPM 20-10-19 as an ac-
cepted procedure.
-BMS 13-54, Type 3,
Class 1, Red
Lacing Tape
Refer to SWPM 20-10-18 as an ac-
cepted procedure.
2280N3355-10103Sleeve3
Refer to SWPM 20-64-18 as an ac-
cepted procedure. (a)
2M39029/57-359Socket Contact4
Refer to SWPM 20-30-11 as an ac-
cepted procedure.
2BACT12AC-12Terminal Lug5
(a) Isopropyl alcohol is applied to the installation tool and on the contact before installation of
the contact. Isopropyl alcohol is a lubricant that helps with installation of the contact in the
connector.
FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
50 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 51 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
NH00 - 0000t00
W2304
W2304
J5
-TB5028
INBD
" FWD  1423015
FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD
(SHEET 1 OF 1)
Original Issue: July 19, 2006
Revision 3 December 16, 2011l  757-30-0019
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  51 of 56

### Page 52

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
CAUTION: DO NOT CUT THE STRUCTURE BELOW THE BULB SEAL. THE WINDOW SILL IS A HIGH
MOISTURE AREA AND MOISTURE CAN CAUSE CORROSION IF THE FINISH IS DAMAGED.
DAMAGE TO THE FINISH MUST BE REPAIRED.
to clear the new ter-
minal. (a)
1233T8300-8Bulb SealCut1
(b)--GlareshieldIdentify2
(a) If the finish below the bulb seal is damaged, it will need to be sealed with chemical treatment and primer.
Refer to SOPM 20-41-02 and SOPM 20-43-03 as accepted procedures.
FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD
(SHEET 1 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
52 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 53

MORE DATAQTYIDENTIFICATIONNAMETASKSTEP
(b) Part Mark with service bulletin number before new windshield is installed. Refer to SOPM 20-50-10 as
an accepted procedure.
FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
53 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 54 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
W2314
+ A-AA +
D3270
4 A-AB +
D3272
+ A-AC +17
D3274
TB5038
STA 223  B38 RIGHT WINDOW 1
WL 230
RBL 40
0001-12 -  =1
J1
0002-12
J5
B38 RIGHT WINDOW 1
REFERENCE: WIRING DIAGRAM 30-41-12
ADDED WIRE OR NEW ROUTING
FAT DELETED WIRE OR FORMER ROUTING
FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD
(SHEET 1 OF 2)
Original Issue: July 19, 2006
Revision 3 December 16, 2011  BOEING PROPRIETARY -  757-30-0019
Copyright © Unpublished Work - See page 1 for details.  54 of 56

### Page 55

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
MORE DATAQTYIDENTIFICATIONNAMEFLAG
NOTE
1BMS 13-60, Type 1,
Class 1, AWG 12
Wire1
1BMS 13-60, Type 1,
Class 1, AWG 12
Wire2
or optional BACS38K5F Tie Strap.
Green is for right channel separation.
Refer to Standard Wiring Practices
Manual SWPM 20-10-19 as an accept-
ed procedure.
-BMS 13-54, Type 3,
Class 1, Green
Lacing Tape
Refer to SWPM 20-10-18 as an accept-
ed procedure.
2280N3355-10203Sleeve3
Refer to SWPM 20-64-18  as an ac-
cepted procedure. (a)
2M39029/57-359Socket Contact4
Refer to SWPM 20-30-11 as an accept-
ed procedure.
2BACT12AC-12Terminal Lug5
(a) Isopropyl alcohol is applied to the installation tool and on the contact before installation of
the contact. Isopropyl alcohol is a lubricant that helps with installation of the contact in the
connector.
FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD
(SHEET 2 OF 2)
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.
Original Issue: July 19, 2006
757-30-0019Revision 3 December 16, 2011
55 of 56
BOEING SERVICE BULLETIN 757-30-0019

### Page 56 (OCR)

BOEING SERVICE BULLETIN 757-30-0019
W2314
W2314
J5
TB5038
INBD
FWD •  1423016
FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD
(SHEET 1 OF 1)
Original issue: July 19, 2006
Revision 3 December 16, 2011  757-30-0019
BOEING PROPRIETARY -
Copyright © Unpublished Work - See page 1 for details.  56 of 56

---
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