July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 58 

### Commercial **Airplane Group**  

# 757

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 757-30-0019** Date: July 19, 2006 Revision 2: April 19, 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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or otherwise.**BLANK PAGE** July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGE**Table of Contents** July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**Table of Contents** Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 28 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 28 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 29 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 34 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 35 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 41 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . 46 FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . 51 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 52 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . . . . . . . . 54 FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . 55 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD. 56 FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . . . . . . . 58**Table of Contents** July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGEOriginal Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 58 

### Commercial **Airplanes** 

# 757

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 757-30-0019** 

### Revision Transmittal Sheet Original Issue: July 19, 2006 Revision 2: April 19, 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 will now 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. In Planning Information 1.E., Compliance, the compliance table has been changed to add the inspection of windshield J1 and J4 lugs and terminals. 4. In Planning Information 1.G., Manpower, manpower tables have been changed to add time for inspections of the J1 and J4 lugs and terminals. 5. 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. 6. In Planning Information 1.K.2., Publications Affected, Damage Tolerance Based Structural Inspection evaluation statement has been added.Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

7. In Material Information 2.C.1., Kits/Parts, the kit table has been changed to show that the 280N3355-1 wire kit contains the -101 kit and 280N3355-2 wire kit contains the -102 kit. 8. 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. 9. In Figure 1 and Figure 2 the illustration has been changed to add the inspection of the J1 and J4 lugs and terminals. 10. In Figure 1 and Figure 2 new illustrations have been added to show the installation of the lug and the correct alignment of the lug on the terminal. 11. 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. 12. 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: April 19, 2010Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 58 

### Commercial **Airplanes** 

# 757

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 757-30-0019** 

### Summary Original Issue: July 19, 2006 Revision 2: April 19, 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.Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 58 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. **ACTION** (PRR 54530-265S) In the flight compartment, do an 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** 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 4.75Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**482078 CUT THE BULB SEAL AND CUT THE BULB SEAL AND WORK PACKAGE 4: REPLACE THE RIGHT WINDSHIELD. CHANGE THE RELATED WIRING.

INSPECT THE RIGHT WINDSHIELD WORK PACKAGE 2:

WORK PACKAGE 3:

CHANGE THE RELATED WIRING. REPLACE THE LEFT WINDSHIELD.

INSPECT THE LEFT WINDSHIELD WORK PACKAGE 1:Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGEOriginal Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 58 

### Commercial **Airplanes** 

# 757

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 757-30-0019** Original Issue: July 19, 2006 Revision 2: April 19, 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: 757-200 757-200CB 757-200PF IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AIR ASTANA (AKZ) 1 NB561 NT231 NT411–NT412 **GROUP CONFIGURATION DESCRIPTION** 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 2. 2 - 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.Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

AIR CHINA SOUTHWEST BRANCH (XIN) 1 NB291–NB295 NB297–NB299 NB301–NB302 NB327 NT201–NT202 AIR FINLAND (FNL) 1 NB221 NB239 NB454 AIR GREENLAND AS (GRL) 1 NA350 AIR ITALY (RIT) 1 NC057 NE162–NE164 AIR ITALY POLSKA (IPL) 1 NE301 AIRBALTIC CORPORATION (BCB) 1 NT905 NT907 ALADIA AIRLINES (TPT) 1 NA194 NC066 AMERICA WEST AIRLINES (AMW) 1 NB039 AMERICAN AIRLINES (AAL) 1 ND011–ND044 ND046–ND059 ND111–ND113 ND161–ND166 ND168–ND199 NT352 NT731–NT750 NT971–NT985 ARROW AIR (ARW) 1 NA025 ASTRAEUS, LTD. (AUA) 1 NB134 NB142 NB204 NB225 ND401 ATLASJET AIRLINES (ABE) 1 NT375 NT910–NT911 AURELA (URE) 1 NT285 AVIANCA (AVI) 1 NA341 NA347 NA351 NA406 NB070 NB324 NB326 AVIATION CAPITAL GROUP (CGP) 1 NA348 AWAS (AWW) 1 NB133 NB135Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

AZERBAIJAN AIRLINES (AHY) 1 ND248 NT437–NT438 BABCOCK & BROWN A/C MANAGEMENT (BBB) 1 NC062 NT281 NT283 BELAIR AIRLINES (BLB) 1 NT426–NT427 BLUE CITY HOLDING (BCY) 1 NB141 BLUE PANORAMA AIRLINES (BPA) 1 NC094 NT351 BOEING CAPITAL CORPORATION (ZMF) 1 NE302 BRITISH AIRWAYS (BAB) 1 NA237–NA239 NA303–NA305 NA398 NB581–NB583 NT401–NT403 CAM (CGM) 1 NA520 CARGOJET AIRWAYS LTD. (WNT) 1 NA343 CEBU PACIFIC AIR (CEB) 1 NA301–NA302 CHINA SOUTHERN AIRLINES (GUN) 1 NA349 NB065–NB066 NB261–NB267 NB296 CHINA XINJIANG AIRLINES (XIJ) 1 NB325 NB328 NT381–NT386 NT408–NT409 CONTINENTAL AIRLINES (CAL) 1 ND301–ND322 NT751–NT769 CORPORACION YGNUS AIR (REI) 1 NA395 ND241 DELTA AIR LINES (DAL) 1 NA501–NA519 NA521–NA586 NB001–NB004 NC076–NC084 NC091 NC093 NE008 NT353–NT354 NT360 NT371–NT373 NT701–NT730 DHL INTERNATIONAL (DHI) 1 NA201–NA204 NA206–NA213 NA215–NA236 EAGLE AVIATION (EAE) 1 NC052 NC067Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

EL AL ISRAEL AIRLINES (ELA) 1 ND002 ND004–ND007 ESTADO NACIONAL ARGENTINO ENA (ESA) 1 NB144 ETHIOPIAN AIRLINES (ETH) 1 NC092 NE201–NE204 NT248 NT282 NT356 2 NC951 EUROATLANTIC AIRWAYS (MAE) 1 NA196–NA197 EUROPEAN AIR TRANSPORT (EPT) 1 NC059 2 NC974 EVERGREEN A/C SALES & LEASING (EVG) 1 NA006 NA008 FAR EASTERN AIR TRANSPORT (FAT) 1 NT881–NT885 2 NC973 FEDEX (FED) 1 NA346 NA394 NA444 NB064 NB073 NB131–NB132 NB140 NB167 NB424 NB501 NB503 NB508 FINNAIR (FIN) 1 NT341–NT347 FLYGLOBESPAN.COM (FGS) 1 NB224 FUNAIR (FUN) 1 NT909 GENERIC CUSTOMER/SUPPLIER (XXX) 1 NC023 HOLA AIRLINES (HLB) 1 NA399 HONEYWELL AEROSPACE (SGC) 1 NA005 IBERIA AIRLINES (IBE) 1 NT906 NT908Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

ICELANDAIR (ICE) 1 NA028 NB079 NB138–NB139 NB421 ND201–ND203 ND244–ND247 NN001–NN002 NT861–NT862 NT913 NT915–NT916 2 NC971 ILFC (ILF) 1 NC056 NC072–NC073 JET2.COM LTD (CEX) 1 NA344 NA396–NA397 NB061–NB063 NB071–NB072 NB145 JETWORKS LEASING (JTW) 1 NA442 KRASAIR (ZXD) 1 NT901–NT904 L-3 C.I.S. (CIJ) 1 NB146–NB148 NC051 NC070 NC075 NT436 LEGATUM (LGM) 1 NC060 LITHUANIAN AIRLINES (LIJ) 1 NB434 L'AVION (EYS) 1 NE003 NE166 MACQUARIE AIR FINANCE (ZGT) 1 NA026 NC058 MEXICANA (CMA) 1 NT376–NT378 MEXICO'S PRESIDENTIAL AIRCRAFT (MXG) 1 NA027 MID EAST JET (SKL) 1 NC161 MONARCH AIRLINES (MON) 1 NA401–NA405 NA407–NA408 NASA (NAS) 1 NA002 NORTH AMERICAN AIRLINES (NNA) 1 NB236 NT239–NT240 NT242 NT247Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

NORTHWEST AIRLINES (NWA) 1 NC001–NC022 NC024–NC033 NE311–NE325 NU031–NU038 OCEANAIR AIRLINES (OAL) 1 NB453 OMNI AIR INTERNATIONAL (OAE) 1 NA446 NB137 ORIENT THAI AIRLINES (OTH) 1 NA193 PACE AIRLINES (PIE) 1 ND242 PARADIGM AIR (PGD) 1 NA205 PRIMARIS AIRLINES INC. (PIM) 1 NA199 NB067 NE161 PRIVATAIR (PTS) 1 NB136 PRIVILEGE STYLE (PVG) 1 ND243 RAK AIRWAYS (RKW) 1 NT914 ROLLS-ROYCE NORTH AMERICA (RRN) 1 ND001 ND003 ROYAL AIR MAROC (RAM) 1 NC041–NC042 ROYAL BRUNEI AIRLINES (RBA) 1 NB052 ROYAL NEPAL AIRLINES (RNA) 1 ND891 ND895 ROYAL NEW ZEALAND AIR FORCE (RNZ) 1 NB451–NB452 RYAN INTERNATIONAL AIRLINES (RYN) 1 NA195 NA198 NA342 SANTA BARBARA AIRLINES C.A. (YDJ) 1 NA392–NA393 NB068 SAUDI ROYAL FLIGHT (SRF) 1 NB168Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

SHANGHAI AIRLINES (SHA) 1 NE004–NE007 NJ551–NJ555 NT358 SHANGHAI AIRLINES CARGO (CIX) 1 NE001–NE002 SKYSERVICE AIRLINES (SKB) 1 NA345 STATE AIR COMPANY "BERKUT" (ORE) 1 NB053 SUNEXPRESS (SNS) 1 NC068–NC069 NC071 TACV-CABO VERDE AIRLINES (TCV) 1 NC074 NT379 THE YUCAIPA COMPANIES (YUC) 1 NB312 THOMAS COOK AIRLINES UK (JMA) 1 NA445 NB201 NB222–NB223 NB226–NB228 NB230 NB330–NB331 NB446 NB571 NT232–NT234 NT237–NT238 THOMSONFLY (BRI) 1 NA352 NA443 NB322 NB329 NB422–NB423 NB426–NB427 NB429–NB430 NB432–NB433 NB435–NB438 NB506–NB507 NJ001–NJ004 NT245–NT246 NT404–NT407 NT431–NT432 TITAN AIRWAYS (TIU) 1 NB323 NT912 TUIFLY NORDIC (TNS) 1 NB428 NB431 TURKMENISTAN AIRLINES (TUE) 1 NB143 NB161–NB162 NT446 UNITED AIR LINES (UAL) 1 NE011–NE088 NE092–NE094 NE141–NE150 NT791–NT796 UPS (UPS) 1 NT001–NT009 2 NC901–NC950 NS601–NS616 US AIR FORCE (USF) 1 NP901–NP904Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

US AIRWAYS (USA) 1 NA003–NA004 NA007 NA009–NA010 NA012–NA016 NA018–NA020 NB021–NB023 NB036–NB038 NB040–NB041 NB502 NB504–NB505 NB509–NB523 NT286 NT288–NT289 UZBEKISTAN AIRWAYS (UZB) 1 NC151 NT355 NT357 NT359 NT441–NT442 VARIG LOGISTICA S.A. (VRG) 1 NA021–NA023 NA441 NA447 VIM AVIA (VIM) 1 NE165 NE167–NE177 NT284 NT287 VULCAN INC. (VUL) 1 NB311 VX CAPITAL PARTNERS (VXC) 1 NC061 XIAMEN AIRLINES (XIA) 1 ND221–ND225 NJ031–NJ032 NN051–NN052 XL AIRWAYS (SBE) 1 NA024 NB321 ZOOM AIRLINES (YFM) 1 NB202–NB203 IDENTIFICATION BY VARIABLE NUMBER **Variable Group** NA002–NA028 1 NA191–NA199 1 NA201–NA239 1 NA301–NA305 1 NA341–NA352 1 NA391–NA399 1 NA401–NA408 1 NA441–NA447 1 NA501–NA586 1 NB001–NB004 1 NB021–NB023 1 NB036–NB041 1 NB051–NB053 1 NB061–NB073 1Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

NB079 1 NB131–NB148 1 NB161–NB162 1 NB166–NB168 1 NB201–NB204 1 NB221–NB228 1 NB230 1 NB236 1 NB239 1 NB261–NB267 1 NB291–NB299 1 NB301–NB302 1 NB311–NB312 1 NB321–NB331 1 NB421–NB438 1 NB446 1 NB451–NB454 1 NB501–NB523 1 NB561 1 NB571 1 NB581–NB583 1 NC001–NC033 1 NC041–NC042 1 NC051–NC052 1 NC056–NC062 1 NC066–NC084 1 NC091–NC094 1 NC151 1 NC161 1 NC901–NC951 2 NC971–NC974 2 ND001–ND007 1 ND011–ND059 1 ND111–ND113 1 ND161–ND199 1 ND201–ND203 1 ND221–ND225 1 ND241–ND248 1 ND301–ND322 1 **Variable Group**Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 58 ND401 1 ND891 1 ND895 1 NE001–NE008 1 NE011–NE088 1 NE091–NE094 1 NE141–NE150 1 NE161–NE177 1 NE201–NE204 1 NE301–NE302 1 NE311–NE325 1 NJ001–NJ004 1 NJ031–NJ032 1 NJ551–NJ555 1 NN001–NN002 1 NN051–NN052 1 NP901–NP904 1 NS601–NS616 2 NT001–NT009 1 NT201–NT202 1 NT231–NT234 1 NT237–NT240 1 NT242 1 NT245–NT248 1 NT281–NT289 1 NT341–NT347 1 NT351–NT360 1 NT371–NT373 1 NT375–NT379 1 NT381–NT386 1 NT401–NT409 1 NT411–NT412 1 NT426–NT427 1 NT431–NT432 1 NT436–NT438 1 NT441–NT442 1 NT446 1 NT701–NT769 1 NT791–NT796 1 **Variable Group**Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 58 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. 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. 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. NT861–NT862 1 NT881–NT885 1 NT901–NT916 1 NT971–NT985 1 NU031–NU038 1 **Variable Group**Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 58 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 is 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. **D. Description** 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. 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. **E. 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. Compliance Table:

**Condition Action Compliance Time**  **(Whichever Occurs First) Repeat Interval**  **(Whichever Occurs Later)**  Windshield that uses screws and lugs for window heat power connection. Replace with windshield that uses pins and sockets for window heat power connection in accordance with Accomplishment Instructions Work Packages 3 and 4. ---- Terminating action for this bulletin.Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 58 PPG Windshield that uses screws and lugs for window heat power connection. Do the actions that follow for J1, J4 and J5 window heat power connections: 1. Inspect the shipside wiring and terminal lug (including cap) look for signs of melted or discolored insulation. 2. Inspect the window terminal blocks, look for signs of melting or distortion. 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. 4. Inspect the terminal lug for looseness. 5. Address the inspection findings as described in Inspection Conditions 1 thru 4. Within 500 flight hours or 150 days, whichever occurs earlier, after the date of Revision 2 to the service bulletin. Every 6000 flight hours or 24 months until windshield is replaced with windshield that used pins and sockets for the window heat power connection in accordance with Accomplishment Instructions Work Packages 3 and 4. Compliance Table:

**Condition Action Compliance Time**  **(Whichever Occurs First) Repeat Interval**  **(Whichever Occurs Later)** Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

GKN Windshield that uses screws and lugs for window heat power connection. Do the actions that follow for J1, J4 and J5 window heat power connections: 1. Inspect the shipside wiring and terminal lug (including cap) look for signs of melted or discolored insulation. 2. Inspect the window terminal blocks, look for signs of melting or distortion. 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. 4. Inspect the terminal lug for looseness. 5. Address the inspection findings as described in Inspection Conditions 1 thru 4. Within 500 flight hours or 150 days, whichever occurs earlier, after the date of Revision 2 to the service bulletin. Every 12,000 flight hours or 48 months until windshield is replaced with windshield that used pins and sockets for window heat power connection in accordance with Accomplishment Instructions Work Packages 3 and 4.

Inspection Condition 1 - If the inspection reveals one or more signs of the following: 1. Melted shipside wire insulation. 2. Discolored shipside wire insulation. 3. Melted terminal lug. 4. Melted cap. 1. Repair or replace shipside wiring as necessary. Refer to Standard Wiring Practices Manual SWPM 20-10-13 as an accepted procedure. 2. If the terminal lug has melted, replace the shipside terminal lug and windshield in accordance with Work Package 1, step 3. and Work Package 2, step 3. Before further flight. ---- Compliance Table:

**Condition Action Compliance Time**  **(Whichever Occurs First) Repeat Interval**  **(Whichever Occurs Later)** Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

Inspection Condition 2 - If the inspection reveals one or more signs of the following:
1. Melted window terminal block. 2. Distorted or cracked window terminal block. 1. Replace windshield in accordance with Work Package 1, step 3. and Work Package 2, step 3. Before further flight. ----

Inspection Condition 3 - If the inspection reveals evidence the window heat power connection is cross threaded. 1. Inspect the terminal for looseness. If the cross threaded terminal is loose: torque the terminal screw to 25-30 in-lb. 2. Re-inspect terminal lug for looseness. 3. If terminal lug is still loose replace windshield in accordance with Work Package 1, step 3. and Work Package 2, step 3. Before further flight. ----

4. If terminal lug is tight, replace windshield in accordance with Work Package 1, step 3. and Work Package 2, step 3. Within 150 days or 500 flight hours, whichever occurs earlier, after the inspection. ----

Inspection Condition 4 - If the inspection reveals the terminal lug is loose. 1. Torque the terminal screw to 25-30 in-lb. 2. Re-inspect terminal lug for looseness. 3. If terminal lug is still loose then disassemble, inspect and reassemble the electrical connection. Before further flight. ---- Compliance Table:

**Condition Action Compliance Time**  **(Whichever Occurs First) Repeat Interval**  **(Whichever Occurs Later)** Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**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. **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 If the windshield is replaced with same type windshield that uses screws and lugs for window heat power connection. OR Window heat power connection is reassembled (on windshields that uses screws and lugs for window heat power connection). Do a detailed inspection in accordance with Accomplishment Instructions Work Package 1, step 2. and Work Package 2, step 2. Within 150 days or 500 flight hours, whichever occurs earlier, after installation of same windshield type (a). ----

(a) The inital inspection after installing a new window or a new termial 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 followed. Refer to either condition "Window heat power connection is reassembled" or "windshield is replaced with same type windshield" in the Compliance Table for inspection requirements. Compliance Table:

**Condition Action Compliance Time**  **(Whichever Occurs First) Repeat Interval**  **(Whichever Occurs Later)** Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

— Time to find the tools.

**H. Weight and Balance Changes**
None Work Package 1 - Inspection of the Left Windshield
**Task Number of**  **Persons Task-Hours Elapsed Hours** Figure 1 1 1.50 1.50 Total per Windshield 1.50 1.50 Work Package 2 - Inspection of the Right Windshield
**Task Number of**  **Persons Task-Hours Elapsed Hours** Figure 2 1 1.50 1.50 Total per Windshield 1.50 1.50 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 Install the Right Windshield 2 3.0 1.5 Tests 1 0.25 0.25 Close 2 1.0 0.50 Total per Windshield 8.5 4.75Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**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. 757 Aircraft Maintenance Manual (AMM) 30-41-00, 56-11-01 d. Wiring Diagram 30-41-11, 30-41-12 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, 20-63-19, 20-64-16 f. 757 Illustrated Parts Catalog (IPC) 30-41-52 g. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-10 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

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. **Publication Chapter-Section** 757 Maintenance Manual 30-41, 56-11 757 Wiring Diagram Manual 30-41 757 Illustrated Parts Catalog 56-11Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information.Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGEJuly 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kit shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown below. Kit availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date Boeing gets the purchase order.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA **B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **Kit Number Name ROLT**  **(Weeks) Unit Price thru**  **Dec 31/07** 012N8926-7 Top Kit - Left Windshield - PPG with hydrophobic coating 19 $16,480.00 012N8926-8 Top Kit - Right Windshield - PPG with hydrophobic coating 19 $16,480.00July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**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**

**New Part Number QTY**  **Name Notes -8 -7**  012N8926-7 . - Top Kit - Left Windshield, PPG with Hydrophobic coating 012N8926-8 - . Top Kit - Right Windshield, PPG with Hydrophobic coating 141W7400-43 . 1 PPG Left Windshield Assembly with Hydrophobic coating (a) (b) (c) (d) (f) (h) (j) 141W7400-44 1 . PPG Right Windshield Assembly with Hydrophobic coating (a) (b) (c) (e) (g) (i) (j) 280N3355-1 . 1 Wire Kit - Flight Deck Window Heat 280N3355-2 1 . Wire Kit - Flight Deck Window Heat (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 with serial numbers 04001Hxxxx through 05365Hxxxx. (e) As an option operators can install Right Windshield part number 141T4801-60 with serial numbers 04001Hxxxx through 05365Hxxxx. (f) As an option operators can install Left Windshield part number 141W7400-31 or 141W7400-33 with serial numbers 04001Hxxxx through 05365Hxxxx. (g) As an option operators can install Right Windshield part number 141W7400-32 or 141W7400-34 with serial numbers 04001Hxxxx through 05365Hxxxx. (h) As an option operators can install Left Windshield part number 141W7400-35 or 141W7400-41. (i) As an option operators can install Right Windshield part number 141W7400-36 or 141W7400-42. (j) PPG Aerospace - Transparencies Div Glass (V53117) P.O. Box 2200 1719 U.S. Highway 72 East Huntsville, AL 35811-9660July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**Kit 280N3355 New Part**  **Number QTY**  **Name Notes -102 -101 -2 -1**  280N3355-1 . . . - Wire Kit - Flight Deck Window Heat 280N3355-2 . . - . Wire Kit - Flight Deck Window Heat 280N3355-101 . - . 1 Kit, Wire Bundle W2304 280N3355-102 - . 1 . Kit, Wire Bundle W2314 280N3355-10103 . 1 . . BMS 13-52 Expandable Sleeve 280N3355-10203 1 . . . BMS 13-52 Expandable Sleeve - . 1 . . Wire Identified W2304-0001-12 (a)
- . 1 . . Wire Identified W2304-0002-12 (b)
- 1 . . . Wire Identified W2314-0001-12 (a)
- 1 . . . Wire Identified W2314-0002-12 (b) BACT12AC-12 3 3 . . Terminal Lug (c) M39029/57-359 3 3 . . Socket Contact (c) (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.July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

2. Parts and Materials Supplied by the Operator:

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.

4. Parts Removed and Not Replaced: None **D. Parts Necessary to Change Spares**
None **Part Number / Specification QTY Name Notes**  BMS 13-54 10 feet Lacing Tape, Red (a) (b) (c) BMS 13-54 10 feet Lacing Tape, Green (a) (b) (d) (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. (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.

**Existing Part Number QTY Name New Part Number Notes**  233N8300-( ) 1 Glareshield - (a) (b) (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.July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**E. Special Tooling - Price and Availability** Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the date the tools will be used.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgement. After the Price date, new price data is applicable. Prices are in United States dollars. Terms: Net 30 days. Reference this service bulletin number and submit purchase order by one of the methods that follow: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 3. Spares Customer Support - MC 36-65 Boeing Spares Department P.O. Box 3707 Seattle, Washington 98124-2207 USA (Service Bulletin 757-30-0019) **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. Purchase Data:
**Tool Kit Number Name Unit Price thru**  **Dec 31/07** A56001-2 (part of Sling Set A56001-15) Windshield Handling Sling $625.00

**Tool Kit Number Name** A56001-2 (part of Sling Set A56001-15) Windshield Handling SlingJuly 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGEOriginal Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**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 — Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, Chapter 51. 5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation 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 on 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. **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 YOUOriginal Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

TOUCH THE TERMINAL. 1. Open the circuit breaker shown below and attach a DO-NOT-CLOSE tag to it:

2. Do an inspection of the left windshield as given in Figure 1. 3. If the left windshield is not in a serviceable condition, replace the windshield before the subsequent revenue flight. Refer to 757 AMM 56-11-01 as an accepted procedure. 4. Remove the DO-NOT-CLOSE tag and close the circuit breaker shown below:

**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:

2. Do an inspection of the right windshield as given in Figure 2. 3. If the right windshield is not in a serviceable condition, replace the windshield before the subsequent revenue flight. Refer to 757 AMM 56-11-01 as an accepted procedure. 4. Remove the DO-NOT-CLOSE tag and close the circuit breaker shown below:

**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 **Airplane Group**  **Location Panel / Position Name Circuit Breaker**  1 P70 / C13 WINDOW HEATER 1L C391 2 P31 / A05 WINDOW HEATER 1L C391

**Airplane Group**  **Location Panel / Position Name Circuit Breaker**  1 P70 / C13 WINDOW HEATER 1L C391 2 P31 / A05 WINDOW HEATER 1L C391

**Location Panel / Position Name Circuit Breaker**  P37 / J2 WINDOW HEATER 1R C392

**Location Panel / Position Name Circuit Breaker**  P37 / J2 WINDOW HEATER 1R C392Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

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:

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 as given in Figure 3. 4. Change the wiring for the window heat on the left windshield as given in 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:

6. Remove the DO-NOT-CLOSE tag and close this circuit breaker:

7. Do the test "Operational Test - Flight Compartment Window Anti-Icing System" as given in 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: **Airplane Group**  **Location Panel / Position Name Circuit Breaker**  1 P70 / C13 WINDOW HEATER 1L C391 2 P31 / A05 WINDOW HEATER 1L C391

**Description Part Number Part of Top Kit** PPG with Hydrophobic Coating 141W7400-43 012N8926-7

**Airplane Group**  **Location Panel / Position Name Circuit Breaker**  1 P70 / C13 WINDOW HEATER 1L C391 2 P31 / A05 WINDOW HEATER 1L C391

**Location Panel / Position Name Circuit Breaker**  P37 / J2 WINDOW HEATER 1R C392Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

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 as given in Figure 6. 4. Change the window heat wiring for the right windshield as given in Figures 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:

6. Remove the DO-NOT-CLOSE tag and close this circuit breaker:

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. **Description Part Number Part of Top Kit** PPG with Hydrophobic Coating 141W7400-44 012N8926-8

**Location Panel / Position Name Circuit Breaker**  P37 / J2 WINDOW HEATER 1R C392**FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD** Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD** 

FWD INBD TERMINAL BLOCK, CONNECTOR 1 SCREW 3 J4

2 LUG J5 J1

TB5028 W 2 3 0 4

4 5 2 LUG SCREW 3 4 5 SCREW 3 4 5

2 LUG 1 1
TERMINAL BLOCK, CONNECTOR TERMINAL BLOCK, CONNECTOR482068

**(SHEET 1 OF 5) FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

LUG PARALLEL TO TERMINAL LUG (WB0710 SHOWN)

TERMINAL

ACCEPTABLE LUG PARALLEL TO TERMINAL LUG NOT PARALLEL TO TERMINAL LUG (WB0710 SHOWN)

TERMINAL

NOT ACCEPTABLE LUG NOT PARALLEL TO TERMINAL


### WALLACE AND BLACK LUG

CORY / TRI-STAR LUG TERMINAL TERMINAL LUG (CWC01-1210 SHOWN) LUG (CWC01-1210 SHOWN) LUG NOT PARALLEL TO TERMINAL AND O-RING NOT EVENLY COMPRESSED LUG PARALLEL TO TERMINAL AND O-RING EVENLY COMPRESSED

ACCEPTABLE LUG PARALLEL TO TERMINAL NOT ACCEPTABLE LUG NOT PARALLEL TO TERMINAL1650853

**(SHEET 2 OF 5) FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

TERMINAL LUG SCREW

LOCKWASHER COVER

SCREW

LOCKWASHER

COVER

O-RING 

### WALLACE AND BLACK LUG

LUG

TERMINAL 1 1 5 4 3

5 5 4

5 4 3

5 5 4

5



### CORY / TRI-STAR LUG

4 2 4 6 7

4

1 2 4 6

1 4 1 31698037

**(SHEET 3 OF 5) FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **STEP TASK NAME IDENTIFICATION QTY MORE DATA**

1 Inspect Terminal Block J1, J4, J5 3 At the J1, J4 and J5 connections Lug - 3 Wiring Wire bundle W2304 3 **NOTE:** If the terminal lug or cap has melted, replace the shipside terminal lug and windshield. **NOTE:** If the terminal block has melted, distorted or cracked, replace the windshield. **NOTE:** 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.

2 Inspect Lug - 3 To make sure it is a tight connection and not cross threaded. **NOTE:** 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 and Illustrated Parts Catalog 757 IPC 30-41-52. 4-The screw is cross threaded. **NOTE:** 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. **NOTE:** If the lug shows signs of arcing, blueing, overheating or melting, replace the lug and windshield. **CAUTION:** DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.

3 Torque Screw - 3 To 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. Inspect Lug - 3 To make sure the connection is tight. **NOTE:** 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. **NOTE:** If the cross threaded screw can not be tightened, replace the window.

**(SHEET 4 OF 5) FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

4 Remove/ Keep Cover - 3
Remove Screw - 3 To make sure the correct screw is installed and there is no damage to terminal, lug or screw. Washer - 3 Inspect Terminal J1, J4, J5 3 To make sure the terminal or lug is not damaged. Lug - 3 **NOTE:** 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 or overheating, the window must be replaced. **NOTE:** 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 or overheating, the lug must be replaced. **CAUTION:** DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.

5 Install (New) Screw - 3 To make sure lug is assembled to terminal with new, undamaged and correct hardware. Washer - 3 O-ring - 3 **NOTE:** Reassemble the lug to the terminal with a new screw, lock washer and o-ring. Make sure the o-ring is installed prior to assemble of the lug to the terminal. A new o-ring is only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 and 757 IPC 30-41-52 for the correct screw, washer and o-ring. **NOTE:** Make sure the screw has been aligned correctly. Torque Screw - 3 To 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. Install/ Kept Cover - 3
**NOTE:** Do step 2 to make sure the screw has been installed correctly and is a tight connection.

6 Inspect Lug - 3 Apply light manual pressure to strain-relief on lug. **NOTE:** If the lug moves with light manual pressure, replace the windshield. **STEP TASK NAME IDENTIFICATION QTY MORE DATA**

**(SHEET 5 OF 5) FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**

FWD INBD TERMINAL BLOCK, CONNECTOR 1 J4

SCREW 3

LUG 2 J5 J1 W

2 3 1 4

TB5038 4 5 SCREW 3 4 5

1 TERMINAL BLOCK, CONNECTOR 2 LUG SCREW 3 4 5

2 LUG 1 TERMINAL BLOCK, CONNECTOR482071

**(SHEET 1 OF 5) FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

LUG PARALLEL TO TERMINAL LUG (WB0710 SHOWN)

TERMINAL LUG NOT PARALLEL TO TERMINAL LUG (WB0710 SHOWN)

TERMINAL



### WALLACE AND BLACK LUG

TERMINAL TERMINAL LUG (CWC01-1210 SHOWN) LUG (CWC01-1210 SHOWN) LUG NOT PARALLEL TO TERMINAL AND O-RING NOT EVENLY COMPRESSED LUG PARALLEL TO TERMINAL AND O-RING EVENLY COMPRESSED ACCEPTABLE LUG PARALLEL TO TERMINAL NOT ACCEPTABLE LUG NOT PARALLEL TO TERMINAL



### CORY / TRI-STAR LUG ACCEPTABLE LUG PARALLEL TO TERMINAL NOT ACCEPTABLE LUG NOT PARALLEL TO TERMINAL1650854

**(SHEET 2 OF 5) FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

TERMINAL LUG SCREW

LOCKWASHER COVER

TERMINAL SCREW

LOCKWASHER COVER

O-RING 

### WALLACE AND BLACK LUG

LUG 1

1 4

5 4 3

5 1 5 4

1 5 4 3

5 5 4

5



### CORY / TRI-STAR LUG 2 6
1 3

4

1 4 2 6 1 3

41672512

**(SHEET 3 OF 5) FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 49 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **STEP TASK NAME IDENTIFICATION QTY MORE DATA**

1 Inspect Terminal Block J1, J4, J5 3 At the J1, J4 and J5 connections Lug - 3 Wiring Wire bundle W2304 3 **NOTE:** If the terminal lug or cap has melted, replace the shipside terminal lug and windshield. **NOTE:** If the terminal block has melted, distorted or cracked, replace the windshield. **NOTE:** 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.

2 Inspect Lug - 3 To make sure it is a tight connection and not cross threaded. **NOTE:** 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 and Illustrated Parts Catalog 757 IPC 30-41-52. 4-The screw is cross threaded. **NOTE:** 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. **NOTE:** If the lug shows signs of arcing, blueing, overheating or melting, replace the lug and windshield. **CAUTION:** DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.

3 Torque Screw - 3 To 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. Inspect Lug - 3 To make sure the connection is tight. **NOTE:** 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. **NOTE:** If the cross threaded screw can not be tightened, replace the window.

**(SHEET 4 OF 5) FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 50 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

4 Remove/ Keep Cover - 3
Remove Screw - 3 To make sure the correct screw is installed and there is no damage to terminal, lug or screw. Washer - 3 Inspect Terminal J1, J4, J5 3 To make sure the terminal or lug is not damaged. Lug - 3 **NOTE:** 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 or overheating, the window must be replaced. **NOTE:** 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 or overheating, the lug must be replaced. **CAUTION:** DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.

5 Install (New) Screw - 3 To make sure lug is assembled to terminal with new, undamaged and correct hardware. Washer - 3 O-ring - 3 **NOTE:** Reassemble the lug to the terminal with a new screw, lock washer and o-ring. Make sure the o-ring is installed prior to assemble of the lug to the terminal. A new o-ring is only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 and 757 IPC 30-41-52 for the correct screw, washer and o-ring. **NOTE:** Make sure the screw has been aligned correctly. Torque Screw - 3 To 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. Install/ Kept Cover - 3
**NOTE:** Do step 2 to make sure the screw has been installed correctly and is a tight connection.

6 Inspect Lug - 3 Apply light manual pressure to strain-relief on lug. **NOTE:** If the lug moves with light manual pressure, replace the windshield. **STEP TASK NAME IDENTIFICATION QTY MORE DATA**

**(SHEET 5 OF 5) FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD**  July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 51 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD**

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. **STEP TASK NAME IDENTIFICATION QTY MORE DATA 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.

1 Cut Bulb Seal 233T8300-7 - to clear the new terminal. **NOTE:** If the finish below the bulb seal is damaged, it will need to be sealed with chemical treatment and primer. Refer to Standard Overhaul Practices Manual SOPM 20-41-02 and SOPM 20-43-03 as accepted procedures. GLARESHIELD BULB SEAL

1.40 1.20 1482072

**(SHEET 1 OF 1) FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 52 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**FIGURE 4: CHANGES TO TH E WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD** 



### A-AB A-AA

2 1 

# W2304

0001-12 LBL 37 WL 225 STA 225 TB5028

J1 =1

B35 LEFT WINDOW 1 0002-12 J5 =1 B35 LEFT WINDOW 1 A-AC D3324

D3326 =1 =1 D3322 =1

1

2 3

3 5

5

4

4



### ADDED WIRE OR NEW ROUTING DELETED WIRE OR FORMER ROUTING REFERENCE: WIRING DIAGRAM 30-41-11482073

**(SHEET 1 OF 2) FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 53 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**FLAG NOTE NAME IDENTIFICATION QTY MORE DATA**  1 Wire BMS 13-60, Type 1, Class 1, AWG 12 1 2 Wire BMS 13-60, Type 1, Class 1, AWG 12 1 Lacing Tape BMS 13-54, Type 3, Class 1, Red - or optional BACS38K5C Tie Strap. Red is for left channel separation. Refer to Standard Wiring Practices Manual SWPM 20-10-19 as an accepted procedure. 3 Sleeve 280N3355-10103 2 Refer to SWPM 20-10-18 as an accepted procedure. 4 Socket Contact M39029/57-359 2 Refer to SWPM 20-63-19 as an accepted procedure. **NOTE:** 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. 5 Terminal Lug BACT12AC-12 2 Refer to SWPM 20-30-11 as an accepted procedure.

**(SHEET 2 OF 2) FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD**  July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 54 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD**

FWD INBD W2304 W2304 J1

TB5028 J51423015

**(SHEET 1 OF 1) FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 55 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

**FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD**

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. **STEP TASK NAME IDENTIFICATION QTY MORE DATA 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.

1 Cut Bulb Seal 233T8300-8 - to clear the new terminal. **NOTE:** If the finish below the bulb seal is damaged, it will need to be sealed with chemical treatment and primer. Refer to Standard Overhaul Practices Manual SOPM 20-41-02 and 20-43-03 as accepted procedures. 2 Identify Glareshield - (a) (a) Part Mark with service bulletin number before new windshield is installed. Refer to SOPM 20-50-10 as an accepted procedure. GLARESHIELD 1.20 BULB SEAL

1 1.40 2482075

**(SHEET 1 OF 1) FIGURE 7: CHANGES TO THE WIRING FO**  **R THE WINDOW HEAT ON THE RIGHT WINDSHIELD** Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 56 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD** 



### B38 RIGHT WINDOW 1 B38 RIGHT WINDOW 1 RBL 40 WL 230 STA 223 TB5038 D3274 D3272 D3270 

# W2314

=1

=1

=1 A-AC

=1 J5 0002-12 =1 J1 0001-12 1

2 A-AA

A-AB

4 4 5 5

3 3

2 1



### ADDED WIRE OR NEW ROUTING DELETED WIRE OR FORMER ROUTING REFERENCE: WIRING DIAGRAM 30-41-12482076

**(SHEET 1 OF 2) FIGURE 7: CHANGES TO THE WIRING FO**  **R THE WINDOW HEAT ON THE RIGHT WINDSHIELD** Original Issue: July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 57 of 58 

### BOEING SERVICE BU **LLETIN 757-30-0019**

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**FLAG NOTE NAME IDENTIFICATION QTY MORE DATA**  1 Wire BMS 13-60, Type 1, Class 1, AWG 12 1 2 Wire BMS 13-60, Type 1, Class 1, AWG 12 1 Lacing Tape BMS 13-54, Type 3, Class 1, Green - or optional BACS38K5F Tie Strap. Green is for right channel separation. Refer to Standard Wiring Practices Manual SWPM 20-10-19 as an accepted procedure. 3 Sleeve 280N3355-10203 2 Refer to SWPM 20-10-18 as an accepted procedure. 4 Socket Contact M39029/57-359 2 Refer to SWPM 20-63-19 as an accepted procedure. **NOTE:** 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. 5 Terminal Lug BACT12AC-12 2 Refer to SWPM 20-30-11 as an accepted procedure.

**(SHEET 2 OF 2) FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD**  July 19, 2006 Revision 2: April 19, 2010 757-30-0019 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 58 of 58 

### BOEING SERVICE BULLETIN 757-30-0019

**FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD**

J1

J5

FWD INBD TB5038 W2314 W23141423016

**(SHEET 1 OF 1)**