Boeing Special Attention Service Bulletin 757-30-0020: U.S. DOT/FAA -SB-757-30-0020-03, text

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION Number: 757-30-0020 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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.

Original Issue: July 19, 2006 757-30-0020Revision 3: December 16, 2011 1 of 52

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Original Issue: July 19, 2006 757-30-0020Revision 3: December 16, 2011 2 of 52 BOEING SERVICE BULLETIN 757-30-0020

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Table of Contents

Revision Transmittal Sheet5

Summary7

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

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

2. Spares Affected ........................................ 1 2 B. Concurrent Requirements ...................................... 1 2 C. Reason ................................................ 1 2 D. Description .............................................. 1 3 E. Compliance .............................................. 1 3 F. Approval ............................................... 1 7 G. Manpower .............................................. 1 7 H. Weight and Balance Changes .................................... 1 9 I. Electrical Load Data ......................................... 1 9 J. References .............................................. 1 9

1. Existing Data: ......................................... 1 9

2. Data supplied with this Service Bulletin: ........................... 1 9

3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 9 K. Publications Affected ........................................ 1 9 L. Interchangeability and Intermixability of Parts ........................... 2 0

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

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

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

3. Parts Modified and Reidentified: ............................... 2 4

4. Parts Removed and Not Replaced: .............................. 2 4 D. Parts Necessary to Change Spares ................................. 2 4 E. Special Tooling - Price and Availability ............................... 2 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 5

3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 7 A. GENERAL INFORMATION ..................................... 2 7 B. WORK INSTRUCTIONS ....................................... 2 8 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD ......................... 3 1 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD ........................ 3 7 FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD ................... 4 3 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 45 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD ........ 4 7 FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD ................... 4 8 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . 50 FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD ....... 5 2

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION Revision Transmittal SheetNumber: 757-30-0020Original 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 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.

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, changed a Standard Wiring Practices Manual (SWPM) reference and added an Airplane Maintenance Manual (AMM) 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. Footnotes, added an AMM reference.

10. In FIGURE 3, added new step and circle note.

11. In FIGURE 4 and FIGURE 7, flagnote tables, changed a SWPM reference.

The data given in Information Notice 757-30-0020 IN 01 is included in this revision.

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:

March 31, 2010Revision 2:

December 16, 2011Revision 3:

Original Issue: July 19, 2006 757-30-0020Revision 3: December 16, 2011 6 of 52 BOEING SERVICE BULLETIN 757-30-0020

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Commercial Airplanes 757 Service Bulletin

SPECIAL ATTENTION SummaryNumber: 757-30-0020Original 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.

ACTION (PRR 54530-265S) 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.

EFFECTIVITY 757-300 Airplanes. Refer to Paragraph 1.A., Effectivity., 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., Compliance 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 757-30-0020 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: 485171

INSPECT THE LEFT WINDSHIELD Original Issue: July 19, 2006 Revision 3: December 16, 2011 757-30-0020

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Commercial Airplanes 757 Service Bulletin

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.

-1 Airplane Models:

757-300 GroupVariable Number 1NL001 - NL002 1NL006 - NL017 1NL101 - NL109 1NL141 1NL601 - NL616 1NU701 - NU705 1NU721 - NU728

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GroupVariable Number 1NU731 - NU732

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 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.

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.

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.

Revision 1 was sent to change the No.1 Windshield Assembly part numbers supplied in the Top Kits.

Original Issue: July 19, 2006 757-30-0020Revision 3: December 16, 2011 12 of 52 BOEING SERVICE BULLETIN 757-30-0020

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