Boeing Special Attention Service Bulletin 767-30-0039: No revision named, text

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Commercial Airplane Group 767

SPECIAL ATTENTION Service Bulletin Number: 767-30-0039 Date: December 05, 2007 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 24 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 30

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 31

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 38 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . 40 FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . 42 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT WIRING ON THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . . . . . . . . 46 FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . 47 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD. 49 FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . . . . . . . 51

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Commercial Airplane Group 767

SPECIAL ATTENTION Service Bulletin Number: 767-30-0039 Summary Date: December 05, 2007 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 an electrical connection 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. 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 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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Boeing Service Related Problem (SRP) 767-SRP-56-0015 is related to this service bulletin.

ACTION (PRR B12901-56S) In the flight compartment, do an inspection of the J5 terminal 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 767-200/-300/-300F Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE 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 0.25 0.25 Work Package 2 - Inspection of the Right Windshield 0.25 0.25 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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WORK PACKAGE 2:

INSPECT THE RIGHT

WINDSHIELD

INSPECT THE LEFT WINDSHIELD WORK PACKAGE 1:

WORK PACKAGE 3:

CUT THE BULB SEAL AND REPLACE THE LEFT WINDSHIELD.

CHANGE THE RELATED WIRING.

WORK PACKAGE 4:

CUT THE BULB SEAL AND REPLACE THE RIGHT WINDSHIELD.

CHANGE THE RELATED WIRING.

481730

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Commercial Airplane Group 767

1. PLANNING INFORMATION A. Effectivity

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

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR B12901-56S for data about this change.

Airplane models:

767-200 767-300 767-300F

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AA 767 LLC (SVX) 1V E 0 6 7

ABX AIR (ABX) 1 VA301 VA303–VA306 VA309–VA315 VA508 VA803 VA807–VA809 VB101–VB123 VB125 VB302

AEROFLOT (ARO) 1 VL896–VL897 VN471–VN472 VS216–VS217 VS321–VS324 VS392

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

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AEROMEXICO (AMX) 1 VF071 VF093 VF162 VS211

AEROSVIT (UKA) 1 VN154–VN155 VN157

AEROTURBINE (AUB) 1 VB051 VB054–VB055 VB321–VB322

AIR ALGERIE (ALG) 1 VK131–VK133

AIR ASTANA (AKZ) 1 VL899–VL900

AIR CANADA (ACN) 1 VA701–VA709 VA711–VA719 VB001–VB002 VB201–VB202 VN051–VN054 VN056–VN062 VN531 VN536 VN541–VN542 VN546–VN547 VN751–VN752 VN811–VN812 VN931–VN936 VS381–VS382 VS546–VS549

AIR CHINA (BEJ) 1 VE064 VE083–VE086 VK161–VK164 VN388 VS206 VS208 VS274 VS307

AIR DO (HIA) 1 VS176–VS177

AIR EUROPA (ARE) 1 VN638 VS291–VS293

AIR ITALY (RIT) 1 VL913

AIR MADAGASCAR (MAD) 1V N 1 6 7 V N 7 3 1

AIR NEW ZEALAND (ANZ) 1 VN653 VN655–VN658 VS113

AIR NIUGINI (NIU) 1V N 6 5 1

AIR PACIFIC (APC) 1V N 6 7 6

AIR SAHARA (SAQ) 1V N 4 9 5

AIR SEYCHELLES (ASY) 1 VL941 VS526

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AIR TRANSPORT INTERNATIONAL (TIN) 1 VA509–VA513

AIR ZIMBABWE (ZMB) 1 VF061–VF062

ALITALIA (ALI) 1 VL701–VL702 VN422–VN427 VN732 VN813 VS366–VS367 VS401

ALL NIPPON AIRWAYS (ANA) 1 VK081–VK113 VN191–VN198 VR401 VS721–VS730 VT501

AMERICAN AIRLINES (AAL) 1 VA501–VA505 VA514–VA525 VA527–VA530 VN001–VN041 VS196–VS203 VS751–VS759

ARAMCO ASSOCIATED COMPANY (RAS) 1 VR084

ARKEFLY (HXL) 1 VN156 VN164–VN165 VN225

ASIANA AIRLINES (AAR) 1 VK143–VK148 VR426 VW851

AUSTRALIAN AIRLINES (AUF) 1 VN089–VN092 VS486

AUSTRIAN (AUL) 1 VN242–VN243 VN671 VS301–VS303

AVIANCA (AVI) 1 VE171–VE172 VF072 VF092 VF161 VN152 VN532

AWAS (AWW) 1V B 3 2 5

BELAIR AIRLINES (BLB) 1 VL932

BELLVIEW AIRLINES (BEB) 1 VE125–VE126

BLUE CITY HOLDING (BCY) 1V E 0 6 9

BLUE PANORAMA AIRLINES (BPA) 1 VN174 VN681 VS061

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BOEING (TBC) 1 VA001

BRA TRANSPORTES AEREOS (BRW) 1 VA806 VN376

BRAVO AIRLINES (BVA) 1 VE104

BRITISH AIRWAYS (BAB) 1 VN111–VN114 VN118–VN122 VN124–VN127 VN133–VN137 VS246–VS248

CAMEROON AIRLINES (CAM) 1 VA801 VS308

CHINA EASTERN YUNNAN AIRLINES (YUN) 1 VL871–VL873

CONDOR (CDF) 1 VN683–VN691

CONTINENTAL AIRLINES (CAL) 1 VR051–VR060

CROCUS CORPORATION (CCS) 1 VS825

CSDS AVIATION (CSO) 1 VA506–VA507

DELTA AIR LINES (DAL) 1 VA302 VK035–VK056 VL753 VN251–VN276 VN301–VN306 VR471–VR472 VS066–VS070 VS073–VS078 VS266–VS273 VS466–VS472

EDREES AVIATION (SME) 1 VA804

EL AL ISRAEL AIRLINES (ELA) 1 VB281–VB284 VF101–VF102 VN537 VN682 VN972

ERITREAN AIR LINES (ERJ) 1 VE066

ETHIOPIAN AIRLINES (ETH) 1 VE002 VL898 VS306 VS506–VS507 VS881

ETIHAD AIRWAYS (ETI) 1 VS391

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