Boeing Special Attention Service Bulletin 757-30-0020: U.S. DOT/FAA - Service Bulletin (757) (2), text

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Commercial Airplane Group 757

SPECIAL ATTENTION Service Bulletin Number: 757-30-0020 Date: July 19, 2006 Revision 2: March 31, 2010 ATA System: 3041 5611 SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield Inspection and Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document or otherwise.

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Table of Contents Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 19 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 24

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 25

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . 36 FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . 41 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 42 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . . . . . . . . 44 FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . 45 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD 46 FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . . . . . . . 48

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Commercial Airplanes 757

SPECIAL ATTENTION Service Bulletin Number: 757-30-0020 Revision Transmittal Sheet Original Issue: July 19, 2006 Revision 2: March 31, 2010 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 More work is necessary on airplanes changed as shown in the original issue and Revision 1 of this service bulletin.

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.

REASON FOR REVISION This revision is sent to tell operators that have not done the terminating action in the compliance of this service bulletin that they will need to also inspect the J1 and J4 windshield lugs and terminals.

These sections were changed:

1. Summary Background, Planning Information 1.D., Reason and 1.J.1., Existing Data, Service Related Problem (SRP) 757-SRP-30-0031 has been added.

2. Summary Action and Planning Information 1.D., Description, have been changed to add the inspection of the J1 and J4 lugs and terminals.

3. Summary Compliance and Planning Information 1.E., Compliance, a statement has been added to say the Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin.

4. In Planning Information 1.E., Compliance, the compliance table has been changed to add the inspection of windshield J1 and J4 lugs and terminals.

5. In Planning Information 1.G., Manpower, manpower tables have been changed to add the time for inspection of the J1 and J4 lugs and terminals.

6. In Planning Information 1.J.1., Existing Data, Standard Wiring Practices Manual (SWPM) reference 20-64- 16 and Illustrated Parts Catalog (IPC) reference 30-41-52 have been added.

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7. In Planning Information 1.K.2., Publications Affected, Damage Tolerance Based Structural Inspection evaluation Statement has been added.

8. In the Material Information 2.C.1., the kit table has been changed to show that the 280N3355-1 wire kit contains the -101 kit and the 280N3355-2 wire kit contains the -102 kit.

9. In the Work Instructions 3.B., step 3 of Work Packages 1 and 2 has been changed to add new compliance time thresholds for windshield inspections.

10. In Figure 1 and Figure 2 the illustrations have been changed to add the inspection of the J1 and J4 lugs and terminals.

11. In Figure 1 and Figure 2 new illustrations have been added to show the correct alignment of the lug on the terminal.

12. In Figure 1 and Figure 2, step 2, the step table note has changed to show another cause of a loose terminal.

The Standard Overhaul Practices Manual (SOPM) reference 20-43-03 has been changed to Standard Wiring Practices Manual (SWPM) reference 20-64-16 and Illustrated Parts Catalog (IPC) reference 30-41- 52 has been added. New steps have been added to give instructions to inspect the screw if it cannot be tightened in step 3.

13. Figure 6, in the illustration, circle note 2 has been moved to point to an area near the bulb seal. This is the area where the part mark can be applied.

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 Original Issue: July 19, 2006 Revision 1: December 19, 2007 Revision 2:

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Commercial Airplanes 757

SPECIAL ATTENTION Service Bulletin Number: 757-30-0020 Summary Original Issue: July 19, 2006 Revision 2: March 31, 2010 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 an 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 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.

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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.

ACTION (PRR 54530-265S) In the flight compartment, do an 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.

EFFECTIVITY All 757-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.

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

MATERIAL INFORMATION Boeing Supplied Kits/Parts Refer to Paragraph 2.A., Material - Price and Availability.

Work Package Total Task Hours Elapsed Hours Work Package 1 - Inspection of the Left Windshield 1.5 1.5 Work Package 2 - Inspection of the Right Windshield 1.5 1.5 Work Package 3 - Left Windshield Replacement and Wiring Change

8.5 4.75 Work Package 4 - Right Windshield Replacement and Wiring Change

8.5 4.75

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485171

CUT THE BULB SEAL AND

CUT THE BULB SEAL AND WORK PACKAGE 1:

INSPECT THE LEFT WINDSHIELD REPLACE THE LEFT WINDSHIELD.

CHANGE THE RELATED WIRING.

WORK PACKAGE 3:

WORK PACKAGE 2:

INSPECT THE RIGHT WINDSHIELD CHANGE THE RELATED WIRING.

REPLACE THE RIGHT WINDSHIELD.

WORK PACKAGE 4:

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Commercial Airplanes 757

SPECIAL ATTENTION Service Bulletin Number: 757-30-0020 Original Issue: July 19, 2006 Revision 2: March 31, 2010 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.

Airplane models:

757-300

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

ARKIA ISRAELI AIRLINES (ARK) 1 NU731–NU732

BOEING CAPITAL CORPORATION (ZMF) 1 NL006 NL008 NL016–NL017

CONDOR (CDF) 1 NU701–NU705 NU721–NU728

CONTINENTAL AIRLINES (CAL) 1 NL007 NL009–NL015 NL101–NL109

GROUP CONFIGURATION DESCRIPTION 1 - Airplanes with windshields that use screw and lug electrical connections.

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ICELANDAIR (ICE) 1 NL141

NORTHWEST AIRLINES (NWA) 1 NL601–NL616

THOMAS COOK AIRLINES UK (JMA) 1 NL001–NL002

IDENTIFICATION BY VARIABLE NUMBER

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 C. Reason This service bulletin gives instructions to do an 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.

Variable Group NL001–NL002 1 NL006–NL017 1 NL101–NL109 1 NL141 1 NL601–NL616 1 NU701–NU705 1 NU721–NU728 1 NU731–NU732 1

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