Boeing Special Attention Service Bulletin 767-30-0041: No revision named, text

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Commercial Airplane Group 767

SPECIAL ATTENTION Service Bulletin Number: 767-30-0041 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2007 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9, DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue 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 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 13 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 18

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 19

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 26 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . 28 FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . 30 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 32 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . . . . . . . . 34 FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . 35 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD. 37 FIGURE 8: CHANGES TO THE WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Commercial Airplane Group 767

SPECIAL ATTENTION Service Bulletin Number: 767-30-0041 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 767-400ER 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 - Windshield and Wiring Change - Left Side 8.5 4.75 Work Package 4 - Windshield and Wiring Change - Right Side 8.5 4.75

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WORK PACKAGE 3:

CUT THE BULB SEAL AND REPLACE THE LEFT WINDSHIELD.

CHANGE THE RELATED WIRING.WORK PACKAGE 1:INSPECT THE LEFT WINDSHIELD WORK PACKAGE 2:

INSPECT THE RIGHT

WINDSHIELD WORK PACKAGE 4:

CUT THE BULB SEAL AND REPLACE THE RIGHT WINDSHIELD.

CHANGE THE RELATED WIRING.

481099

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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:

767-400ER

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

CONTINENTAL AIRLINES (CAL) 1 VQ071–VQ086

DELTA AIR LINES (DAL) 1 VQ001–VQ021

IDENTIFICATION BY VARIABLE NUMBER

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

Variable Group VQ001–VQ021 1 VQ071–VQ086 1

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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 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.

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.

Boeing Service Related Problem (SRP) 767-SRP-56-0015 is related to this service bulletin.

D. Description In the flight compartment, an inspection is done of the left and the right windshields. A windshield that uses pin and socket electrical connections is installed. The bulb seal is cut to give clearance for terminals that are on the new windshield. When a windshield that uses the pin and socket electrical connections is installed, the related wire bundle is also changed.

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E. Compliance 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.

Compliance Sequence Condition Action Compliance Time Repeat Interval Windshield that uses screws and lugs for the electrical connections Do the Inspections given in Work Packages 1 and 2 Within 500 flight hours after the date on this service bulletin.

Every 6000 flight hours until Work Packages 3 and 4 are done.

Windshield replaced with the same screw and lug type windshield Do the Inspections given in Work Packages 1 and 2.

Within 500 flight hours of windshield replacement.

Every 6000 flight hours until Work Packages 3 and 4 are done.

Windshield that uses screws and lugs for the electrical connections Replace with windshield that uses pins and sockets for the electrical connections No time limit. Terminating action for this bulletin.

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G. Manpower The table below shows an estimate of the task-hours necessary to do this change for each windshield.

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 Task Number of Persons Task-Hours Elapsed Hours Figure 1 1 0.25 0.25 Total per Windshield 0.25 0.25 Work Package 2 - Inspection of the RIght Windshield Task Number of Persons Task-Hours Elapsed Hours Figure 2 1 0.25 0.25 Total per Windshield 0.25 0.25 Work Package 3 - Replacement of the Left Windshield and Changes to the Related Wiring Task Number of Persons Task-Hours Elapsed Hours Access 2 1.0 0.50 Remove the Left Windshield 2 2.5 1.25 Figure 3 - Cut the Bulb Seal 1 0.25 0.25 Figures 4 and 5 - Change the Wiring 1 0.50 0.50 Install the Left Windshield 2 3.0 1.5 Tests 1 0.25 0.25 Close 2 1.0 0.50 Total per Windshield 8.5 4.75 Work Package 4 - Replacement of the Right Windshield and Changes to the Related Wiring Task Number of Persons Task-Hours Elapsed Hours Access 2 1.0 0.50 Remove the Right Windshield 2 2.5 1.25 Figure 6 - Cut the Bulb Seal 1 0.25 0.25 Figures 7 and 8 - Change the Wiring 1 0.50 0.50

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