### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-30-0020**  Original Issue: July 19, 2006 Revision 3: December 16, 2011 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield Inspection and Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work. This document includes proprietary information owned by The Boeing Company and/or one or more third parties. Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, Poseidon and the Boeing livery are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 1 of 52 4.0BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 2 of 52 **BOEING SERVICE BULLETIN 757-30-0020**

BLANK PAGE**Table of Contents** Revision Transmittal Sheet............................................ 5 Summary...................................................... 7 1. PLANNING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Reason. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 D. Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 J. References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2. Data supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 19 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C. Parts Necessary For Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2. Parts and Materials Supplied by the Operator:. . . . . . . . . . . . . . . . . . . . . . . . 23 3. Parts Modified and Reidentified:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4. Parts Removed and Not Replaced:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 25 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . 31 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . 37 FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD. . . . . . . . . . . . . . . . . . . 43 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 45 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD. . . . . . . . 47 FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD. . . . . . . . . . . . . . . . . . . 48 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . 50 FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD. . . . . . . 52

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 3 of 52 **BOEING SERVICE BULLETIN 757-30-0020**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 4 of 52 **BOEING SERVICE BULLETIN 757-30-0020**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Revision Transmittal Sheet**  **Number: 757-30-0020** Original Issue: July 19, 2006 Revision 3: December 16, 2011 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield Inspection and Replacement This revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 is related to this service bulletin. More work is necessary on airplanes inspected in accordance with the original issue or Revision 1 of this service bulletin. No more work is necessary on airplanes inspected in accordance with Revision 2 of this service bulletin. No more work is necessary on airplanes that have done the terminating action in accordance with the original issue or Revision 1 or Revision 2 of this service bulletin. **REASON FOR REVISION** This revision is sent to add Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 and change the text in the Compliance Table. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. These sections were changed: 1. In Summary and Paragraph 1.E., Compliance, added FAA AD 2010-15-01. 2. In Paragraph 1.D., Description, added terminating action statement. 3. In Paragraph 1.E., Compliance, changed the text in the Compliance Table. 4. In Paragraph 1.F., Approval, added Alternative Method Of Compliance (AMOC) paragraph. 5. In Paragraph 1.J.1, Existing Data, changed a Standard Wiring Practices Manual (SWPM) reference and added an Airplane Maintenance Manual (AMM) reference. 6. In Paragraph 2.A., Material - Price and Availability, updated kit price and availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 5 of 527. In Paragraph 2.C.1., Kit/Parts, added new windshield part numbers and serial numbers to the kit table. 8. In Paragraph 2.E., Special Tooling - Price and Availability, updated tool kit price. 9. In FIGURE 1 and FIGURE 2: a. Removed circle notes 6 and 7 and changed the illustrations. b. Footnotes, added an AMM reference. 10. In FIGURE 3, added new step and circle note. 11. In FIGURE 4 and FIGURE 7, flagnote tables, changed a SWPM reference. The data given in Information Notice 757-30-0020 IN 01 is included in this revision. Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes. Pages with no vertical lines have no important changes. **REVISION HISTORY** July 19, 2006 Original Issue: December 19, 2007 Revision 1: March 31, 2010 Revision 2: December 16, 2011 Revision 3:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 6 of 52 **BOEING SERVICE BULLETIN 757-30-0020**

### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Summary**  **Number: 757-30-0020** Original Issue: July 19, 2006 Revision 3: December 16, 2011 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield Inspection and Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS** None **BACKGROUND** This service bulletin gives instructions to do a detailed inspection of the electrical connections on the left and the right windshields. Instructions are also given to replace the windshields and make changes to their related wire bundles. A new windshield design is available that uses a different electrical connection. Boeing received nine reports from eight operators of electrical arcs at the terminal blocks of the flight compartment windows. More than one of these reports included data to show that the results of the arcs were open flame incidents. One operator found an indication of damage at a terminal and tightened a loose connection. The terminal had internal damage that could not be seen. Less than six months after the connection was tightened there was a report from the operator of an open flame incident on the same windshield. The electrical connections on the windows are made with lugs that are attached with screws. The windshield is the number 1 window in the flight compartment. All of the windows in the flight compartment are electrically heated. The windshield gets a much larger electrical load. An investigation found that the cause of the electrical arcs is loose terminal connections. A loose connection increases the heat at the terminal which can cause damage to the internal solder joint. Damaged solder joints are the primary cause for the electrical arcs. The primary causes of loose connections are the incorrect torque of the screw or an incorrectly installed screw. The detailed inspection given in this service bulletin is to look for damage or a loose electrical connection on the windshield. If there are indications of electrical arcs or damage to the electrical connection, the windshield is replaced. If there is a loose electrical connection, the correct torque is applied to tighten it. If a connection cannot be tightened to the correct torque, the windshield is replaced. When a windshield with an electrical connection that uses pins and sockets is installed, the related wire bundle on the airplane is changed. When the changes given in this bulletin are done, the windshields will have better electrical connections. The new connections are made with pins and sockets. The pin and socket connections will prevent the risk of electrical arcs as a result of loose connections.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 7 of 52Boeing Service Related Problems (SRP) 757-SRP-30-0031 and 757-SRP-56-0015 are related to this service bulletin. **ACTION (PRR 54530-265S)** In the flight compartment, do a detailed inspection of the J1, J4 and J5 lugs and terminals on the left and the right windshields. Replace windshields that use screws and lugs for the electrical connections with a windshield that uses pins and sockets for the electrical connections. Cut the bulb seal to give clearance for terminals on the new windshield. Change the related wire bundle. **EFFECTIVITY** 757-300 Airplanes. Refer to Paragraph 1.A., Effectivity., Airplanes for the list of affected airplanes. **COMPLIANCE** Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 is related to this service bulletin. See Service Bulletin Paragraph 1.E., Compliance for compliance information. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **MANPOWER Elapsed Hours**  **Total Task Hours Work Package**  1.5 1.5 Work Package 1 - Detailed Inspection of the Left Wind- shield 1.5 1.5 Work Package 2 - Detailed Inspection of the Right Wind- shield 4.75 8.5 Work Package 3 - Left Windshield Replacement and Wiring Change 4.75 8.5 Work Package 4 - Right Windshield Replacement and Wiring Change
**MATERIAL INFORMATION** Boeing Supplied Kits/Parts Refer to Paragraph 2.A., Material - Price and Availability.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 8 of 52 **BOEING SERVICE BULLETIN 757-30-0020**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 9 of 52 **BOEING SERVICE BULLETIN 757-30-0020**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 10 of 52 **BOEING SERVICE BULLETIN 757-30-0020**

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### Commercial **Airplanes** 

# 757 Service Bulletin **SPECIAL ATTENTION Number: 757-30-0020**  Original Issue: July 19, 2006 Revision 3: December 16, 2011 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield Inspection and Replacement 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.
**DESCRIPTION CONFIGURATION**  **GROUP** Airplanes with windshields that use screw and lug electrical connections. - 1

Airplane Models: 757-300 **Group Variable Number**  1 NL001 - NL002 1 NL006 - NL017 1 NL101 - NL109 1 NL141 1 NL601 - NL616 1 NU701 - NU705 1 NU721 - NU728

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 11 of 52**Group Variable Number**  1 NU731 - NU732 2. Spares Affected Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for the recommended use. **B. Concurrent Requirements** None **C. Reason** This service bulletin gives instructions to do a detailed inspection of the electrical connections on the left and the right windshields. Instructions are also given to replace the windshields and make changes to their related wire bundles. A new windshield design is available that uses a different electrical connection. Boeing received nine reports from eight operators of electrical arcs at the terminal blocks of the flight compartment windows. More than one of these reports included data to show that the results of the arcs were open flame incidents. One operator found an indication of damage at a terminal and tightened a loose connection. The terminal had internal damage that could not be seen. Less than six months after the connection was tightened there was a report from the operator of an open flame incident on the same windshield. The electrical connections on the windows are made with lugs that are attached with screws. The windshield is the number 1 window in the flight compartment. All of the windows in the flight compartment are electrically heated. The windshield gets a much larger electrical load. An investigation found that the cause of the electrical arcs is loose terminal connections. A loose connection increases the heat at the terminal which can cause damage to the internal solder joint. Damaged solder joints are the primary cause for the electrical arcs. The primary causes of loose connections are the incorrect torque of the screw or an incorrectly installed screw. The detailed inspection given in this service bulletin is to look for damage or a loose electrical connection on the windshield. If there are indications of electrical arcs or damage to the electrical connection, the windshield is replaced. If there is a loose electrical connection, the correct torque is applied to tighten it. If a connection cannot be tightened to the correct torque, the windshield is replaced. When a windshield with an electrical connection that uses pins and sockets is installed, the related wire bundle on the airplane is changed. When the changes given in this bulletin are done, the windshields will have better electrical connections. The new connections are made with pins and sockets. The pin and socket connections will prevent the risk of electrical arcs as a result of loose connections. Boeing Service Related Problems (SRP) 757-SRP-30-0031 and 757-SRP-56-0015 are related to this service bulletin. Revision 1 was sent to change the No.1 Windshield Assembly part numbers supplied in the Top Kits.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 12 of 52 **BOEING SERVICE BULLETIN 757-30-0020**Revision 2 was sent to tell operators that have not done the terminating action in the compliance of this service bulletin that they will need to also inspect the J1 and J4 windshield lugs and terminals. Revision 3 is sent to add Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 and change the text in the Compliance Table. Terminology has been changed in the Work Instructions to agree with the terminology defined in Paragraph 3.A., General Information - Notes. The data given in Information Notice 757-30-0020 IN 01 is included in this revision. **D. Description** In the flight compartment, a detailed 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. 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 inspected as shown in original issue of this service bulletin. Revision 2 - More work is necessary on airplanes inspected as shown in the original issue and Revision 1 of this service bulletin. Revision 3 - More work is necessary on the airplanes inspected in accordance with the original issue or Revision 1 of this service bulletin. No more work is necessary on airplanes inspected in accordance with Revision 2 of this service bulletin. No more work is necessary on airplanes that have done the terminating action in accordance with the original issue or Revision 1 or Revision 2 of this service bulletin. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 211, 212 757-300 **E. Compliance** Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 is related to this service bulletin. Boeing recommends that the inspection given in this service bulletin be done within 500 flight hours or 150 days after the effective date of AD 2010-15-01 .

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 13 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Compliance Table:**  **Repeat Interval (Whichever Occurs Later)**  **Compliance Time (Whichever Occurs First)**  **Action Condition**  Terminating action for this bulletin. ---- Replace with wind- shield that uses pins and sockets for window heat power connectionin accordance with Accomplishment Instructions Work Packages 3 and 4. Windshield that uses screws and lugs for window heat power connection.

Every 6000 flight hours or 24months until windshield is replaced with windshield that used pins and sockets forwindow heat power connection in accordance with Accomplishment Instructions Work Packages 3 and 4. Within 500 flight hours or 150 days, after the effective date of AD 2010-15-01.Do the actions that follow for J1, J4 and J5 window heat power connections: 1. Inspect the shipside wiring and terminal lug (including cover), look for signs of melted or discolored insulation. PPG Windshield that uses screws and lugs for window heat power connection.

2. Inspect the window terminal blocks, look forsigns of melting, distortion or cracking. 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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 14 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Compliance Table:**  **Repeat Interval (Whichever Occurs Later)**  **Compliance Time (Whichever Occurs First)**  **Action Condition**  Every 12,000 flight hours or 48 months until windshield is replaced with windshield that used pins and sockets forwindow heat power connection in accordance with Accomplishment Instructions Work Packages 3 and 4. Within 500 flight hours or 150 days, after the effective date of AD 2010-15-01.Do the actions that follow for J1, J4 and J5 window heat power connections: 1. Inspect the shipside wiring and terminal lug (including cover), look for signs of melted or discolored insulation. GKN Windshield that uses screws and lugs for window heat power connection.

2. Inspect the window terminal blocks, look forsigns of melting, distortion or cracking. 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.

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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 15 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Compliance Table:**  **Repeat Interval (Whichever Occurs Later)**  **Compliance Time (Whichever Occurs First)**  **Action Condition** 

---- Before further flight. 1. Replace windshield in accordance with Work Package 1, step 2, or Work Package 2, step 2; as applicable. 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.

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

---- Within 500 flight hours or 150 days after the inspection. 4. If terminal lug is tight, replace windshield in accordance with Work Package 1, step 2, or Work Package 2, step 2; as applicable.

---- Before further flight. 1. Torque the terminal screw to 25-30 in-lb. Inspection Condition 4- If the inspection reveals the terminal lug is loose. 2. Re-inspect terminal lug for looseness. 3. If terminal lug is stillloose then disassemble, inspect and reassemble the electricalconnection in accordance with Package 1,step 2, or Work Package 2, step 2; as applicable.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 16 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Compliance Table:**  **Repeat Interval (Whichever Occurs Later)**  **Compliance Time (Whichever Occurs First)**  **Action Condition** 

---- Within 150 days or 500 flight hours, after the reassembly of the windshield heat power connection. (a)Do a detailed inspection and corrective actions if necessary in accordance with Work Package 1, step 2, or Work Package 2, step 2; as applicable. Window heat powerconnection is reassembled (on windshields that use screws and lugs for window heat power connection). ORIf the windshield is replaced with same type windshield that uses screws and lugs for window heat power connection. (a) The initial inspection after installing a new window or a new terminal 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 Bulletinshould be followed. Refer to either condition "Window heat power connection is reassembled" or "windshield is replaced with the same type windshield" in the Compliance Table for inspection requirements. **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. In addition, the Manager of the FAA Seattle Aircraft Certification Office approves the action (i.e. inspection or modification) defined in this service bulletin as an alternative method of compliance to the requirements of paragraphs (f), (g), (h) and (i) of AD 2010-15-01. All provisions of AD 2010-15-01 that are not specifically referenced in the above statement remain fully applicable and must be complied with. **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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 17 of 52 **BOEING SERVICE BULLETIN 757-30-0020**— 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 Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

1.50 1.50 1 FIGURE 1 1.50 1.50 Total per Windshield **Work Package 2 - Inspection of the Right Windshield Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

1.50 1.50 1 FIGURE 2 1.50 1.50 Total per Windshield **Work Package 3 - Replacement of the Left Windshield and Changes to the Related Wiring Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

0.50 1.0 2 Access 1.25 2.5 2 Remove the Left Windshield 0.25 0.25 1 FIGURE 3 - Cut the Bulb Seal 0.50 0.50 1 FIGURE 4 and FIGURE 5 - Change the Wiring 1.5 3.0 2 Install the Left Windshield 0.25 0.25 1 Tests 0.50 1.0 2 Close 4.75 8.5 Total per Windshield **Work Package 4 - Replacement of the Right Windshield and Changes to the Related Wiring Elapsed Hours**  **Task-Hours Number of Per-**  **sons Task** 

0.50 1.0 2 Access 1.25 2.5 2 Remove the Right Windshield 0.25 0.25 1 FIGURE 6 - Cut the Bulb Seal 0.50 0.50 1 FIGURE 7 and FIGURE 8 - Change the Wiring

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 18 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Work Package 4 - Replacement of the Right Windshield and Changes to the Related Wiring**  **Elapsed Hours Task-Hours**  **Number of Per- sons**  **Task**

1.5 3.0 2 Install the Right Windshield 0.25 0.25 1 Tests 0.50 1.0 2 Close 4.75 8.5 Total per Windshield **H. Weight and Balance Changes** None **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. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2010-15-01 d. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-10 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, 20-64-16, 20-64-18 f. 757 Aircraft Maintenance Manual (AMM) 30-41-00, 56-11-01 g. Wiring Diagram 30-41-11, 30-41-12 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

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 19 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Chapter-Section**  **Publication** 30-41, 56-11 757 Maintenance Manual 30-41 757 Wiring Diagram Manual 56-11 757 Illustrated Parts Catalog 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. **L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 20 of 52 **BOEING SERVICE BULLETIN 757-30-0020 2. MATERIAL INFORMATION**  **A. Material - Price and Availability** Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or The Boeing PART Page 2. Fax to (206) 662-7145 **REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION** 
**Unit Price as of the Revision 03** **date of this Ser vice Bulletin (US**  **Dollars) ROLT as of the**  **Revision 03 date**

**of this Service Bulletin (Calendar**  **Days) Name**  **Kit Number**

$18,647.00 130 Top Kit - Left Windshield - PPG with hy- drophobic coating 012N8926-13 $18,647.00 130 Top Kit - Right Windshield - PPG with hy- drophobic coating 012N8926-14
**B. Industry Support Information** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **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 and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane.
**Kit 012N8926 Notes**  **Name QTY**  **New Part Num- ber**  **-13 -14**  Top Kit - Left Windshield, PPG with Hydrophobic coating - . 012N8926-13 Top Kit - Right Windshield, PPG with Hydrophobic coating . - 012N8926-14

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 21 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Kit 012N8926**  **Notes Name**  **QTY New Part Num-**  **ber -13**  **-14** (a) (b) (c) (d) (f) (h) (j) (l) (m)PPG Windshield Assembly - Left, with Hydrophobic coating 1

. 141W7400-43

(a) (b) (c) (e) (g) (i) (k) (l) (m) PPG Windshield Assembly - Right, with Hydrophobic coating . 1 141W7400-44

Wire Kit - Flight Deck Window Heat - Wire Assembly W2304 1

. 280N3355-1 Wire Kit - Flight Deck Window Heat - Wire Assembly W2314 . 1 280N3355-2 (a) Discard the existing part. (b) This part is 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. (e) As an option operators can install Right Windshield part number 141T4801-60. (f) As an option operators can install Left Windshield part number 141W7400-31 or 141W7400-33 with serial numbers 04001Hxxxx thru 05365Hxxxx or with serial numbers 04001Rxxxx through 05365Rxxxx. (g) As an option operators can install Right Windshield part number 141W7400-32 or 141W7400-34 with serial numbers 04001Hxxxx thru 05365Hxxxx or with serial numbers 04001Rxxxx thru 05365Rxxxx. (h) As an option operators can install Left Windshield part number 141W7400-37 or 141W7400-39 with serial numbers 06001Hxxxx thru 06338Hxxxx or with serial numbers 06001Rxxxx thru 06338Rxxxx. (i) As an option operators can install Right Windshield part number 141W7400-38 or 141W7400-40 with serial numbers 06001Hxxxx thru 06338Hxxxx or with serial numbers 06001Rxxxx thru 06338Rxxxx. (j) As an option operators can install Left Windshield part number 141W7400-35 or 141W7400-41. (k) As an option operators can install Right Windshield part number 141W7400-36 or 141W7400-42. (l) PPG Aerospace - Transparencies Div Glass (V53117) P.O. Box 2200 1719 U.S. Highway 72 East Huntsville, AL 35811-9660 (m) Serial numbers with letter H or R are acceptable. Serial numbers with letter H, are new parts for Boeing production/spares. Serial numbers with letter R are parts rebuilt by PPG.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 22 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Kit 280N3355**  **Notes Name**  **QTY New Part Number**  **-1 -2**  **-101 -102**  Wire Kit - Flight Deck Window Heat - . . . 280N3355-1 Wire Kit - Flight Deck Window Heat . - . . 280N3355-2
Kit, Wire Bundle 1

. - . 280N3355-101 W2304 Kit, Wire BundleW2314

. 1

. - 280N3355-102 BMS 13-52 Expandable Sleeve

. . 1

. 280N3355-10103 BMS 13-52 Expandable Sleeve

. . . 1 280N3355-10203 (a) Wire Identified W2304-0001-12

. . 1

. - (b) Wire Identified W2304-0002-12

. . 1

. - (a) Wire Identified W2314-0001-12

. . . 1

- (b) Wire Identified W2314-0002-12

. . . 1

- (c) Terminal Lug

. . 3 3 BACT12AC-12 (c) Socket Contact

. . 3 3 M39029/57-359 (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. 2. Parts and Materials Supplied by the Operator:
**Notes Name**  **QTY Part Number /**  **Specification** (a) (b) (c) Lacing Tape, Red 10 feet BMS 13-54 (a) (b) (d) Lacing Tape, Green 10 feet BMS 13-54 (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.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 23 of 52 **BOEING SERVICE BULLETIN 757-30-0020**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.
**Notes New Part Number**  **Name QTY**  **Existing Part Number**  (a) (b)

- Glareshield 1 233N8300-( ) (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. 4. Parts Removed and Not Replaced: None **D. Parts Necessary to Change Spares** None **E. Special Tooling - Price and Availability** Boeing can supply the tool(s) shown in Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin. Operators are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin. The tool(s) are subject to the terms and conditions of the Boeing standard purchase order acknowledgement. Prices are in United States Dollars. Terms: Net 30 days. Reference this service bulletin number and submit your purchase order by one of these methods: 1. Order on-line via ATA Spec 2000 or Boeing Part Page 2. Fax to (206) 662-7145 **REFER TO THE BOEING PART PAGE ON MY BOEING FLEET.COM OR CONTACT FIRST RESPONDER AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT)**  **AND PRICE INFORMATION**
**Purchase Data: Unit Price as of**  **the Revision 03 date of this Ser**  **vice Bulletin (US Dollars)**  **Name Tool Kit Number** 

$766.00 Windshield Handling Sling A56001-2 (part of Sling Set A56001- 15)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 24 of 52 **BOEING SERVICE BULLETIN 757-30-0020 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.
**Name Tool Kit Number**  Windshield Handling Sling A56001-2 (part of Sling Set A56001-15)

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 25 of 52 **BOEING SERVICE BULLETIN 757-30-0020**BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 26 of 52 **BOEING SERVICE BULLETIN 757-30-0020**

BLANK PAGE**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 – Hole dimensions for standard solid rivets and fasteners are in Structural Repair Manual (SRM) Chapter 51 5. Refer to the SWPM 20-10-11 and SWPM 20-10-12 for the wire installation procedures, and SWPM 20-10-19 for the wire separation requirements, as accepted 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 in 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. 8. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 9. Where the work instructions include installation of a kept part, a new or serviceable part with the same part number can be installed as an alternative to the kept part. The removed part can be discarded if a new or serviceable part is installed. 10. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 27 of 52 **BOEING SERVICE BULLETIN 757-30-0020 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 YOU TOUCH THE TERMINAL. 1. Open the applicable circuit breaker shown below and attach a DO-NOT-CLOSE tag to it:
**Circuit Breaker Name**  **Position Panel**  C391 WINDOW HTR 1L C13 P70 2. Do a detailed inspection of the left windshield and any corrective actions if necessary, in accordance with FIGURE 1. 3. Remove the DO-NOT-CLOSE tag and close the applicable circuit breaker shown below:
**Circuit Breaker Name**  **Position Panel**  C391 WINDOW HTR 1L C13 P70
**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 this circuit breaker and attach a DO-NOT-CLOSE tag to it:
**Circuit Breaker Name**  **Position Panel**  C392 WINDOW HTR 1R J2 P37 2. Do a detailed inspection of the right windshield and any corrective actions if necessary, in accordance with FIGURE 2. 3. Remove the DO-NOT-CLOSE tag and close this circuit breaker:
**Circuit Breaker Name**  **Position Panel**  C392 WINDOW HTR 1R J2 P37

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 28 of 52 **BOEING SERVICE BULLETIN 757-30-0020 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 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:
**Circuit Breaker Name**  **Position Panel**  C391 WINDOW HTR 1L C13 P70 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 in accordance with FIGURE 3. 4. Change the wiring for the window heat on the left windshield in accordance with FIGURE 4 and FIGURE 5. 5. Do a continuity test of the new wires. 6. 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: **Part of Top Kit Part Number**  **Description** 012N8926-13 141W7400-43 Left Windshield with Hy- drophobic Coating 7. Remove the DO-NOT-CLOSE tag and close this circuit breaker.
**Circuit Breaker Name**  **Position Panel**  C391 WINDOW HTR 1L C13 P70 8. Do the test "Operational Test - Flight Compartment Window Anti-Icing System". Refer to 757 AMM 30-41-00 as an accepted procedure. 9. 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:

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 29 of 52 **BOEING SERVICE BULLETIN 757-30-0020 Circuit Breaker**  **Name Position**  **Panel** C392 WINDOW HTR 1R J2 P37 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 in accordance with FIGURE 6. 4. Change the window heat wiring for the right windshield in accordance with FIGURE 7 and FIGURE 8. 5. Do a continuity test of the new wires. 6. 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: **Part of Top Kit Part Number**  **Description** 012N8926-14 141W7400-44 Right Windshield with Hy- drophobic Coating 7. Remove the DO-NOT-CLOSE tag and close this circuit breaker:
**Circuit Breaker Name**  **Position Panel**  C392 WINDOW HTR 1R J2 P37 8. Do the test "Operational Test - Flight Compartment Window Anti-Icing System". Refer to 757 AMM 30-41-00 as an accepted procedure. 9. Put the airplane in a serviceable condition.

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3: December 16, 2011 30 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  **(SHEET 1 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 31 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  **(SHEET 2 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 32 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  **(SHEET 3 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 33 of 52 **BOEING SERVICE BULLETIN 757-30-0020**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  at the J1, J4 and J5 connection. (a) 3 J1, J4, J5 Terminal Block Inspect 1 (b) 3

- Lug Inspect (c) 3 WIRE BUNDLE W2304 Wiring Inspect 3

- Cover Remove / Keep 2 to make sure it is a tight connection. (d) (e) (f) (g) 3

- Lug Inspect

not necessary if the lug is loose. (h) 3

- Cover Install (Kept)
**CAUTION:** DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.
to 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. (i) (j) 3

- Screw Torque 3

to make sure the connection is tight. 3

- Lug Inspect not necessary if thelug cannot be tightened. 3

- Cover Install (Kept)

to make sure the screw is installedand there is no damage to terminal, lug or screw. 3

- Screw Remove 4

3

- Washer Remove 3

- O-ring Remove to make sure the terminal or lug is not damaged. (k) 3 J1, J4, J5 Terminal Inspect

(l) 3

- Lug Inspect

**FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD (SHEET 4 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 34 of 52 **BOEING SERVICE BULLETIN 757-30-0020 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP CAUTION:**  DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW. to make sure lug isassembled to terminal with new, undamaged and correct hardware. (m) (n) 3

- Screw Install (New) 5

3

- Washer Install (New) (o) 3

- O-ring Install (New) to 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. (p) 3

- Screw Torque

3

- Cover Install (Kept) (a) If the terminal block has melted, distorted or cracked, replace the windshield; refer to 757 AMM 56-11-01 as an accepted procedure. (b) If the terminal lug or cover has melted, replace the shipside terminal lug, refer to SWPM 20-64-16 ; and replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure. (c) 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. (d) 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. 4-The screw is cross threaded. (e) 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. (f) If the lug shows signs of arcing, blueing, overheating or melting, replace the lug, refer to SWPM 20-64- 16 ; and replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure. (g) If the lug is installed correctly, is tight, and is parallel to the terminal block, install the cover. No more work is necessary. (h) If the lug is loose, do step 3. (i) 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. (j) If the cross threaded screw can not be tightened, replace the window. Refer to 757 AMM 56-11-01 as an accepted procedure.

**FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD (SHEET 5 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 35 of 52 **BOEING SERVICE BULLETIN 757-30-0020 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (k) 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, overheating, pitting corrosion or other surface damage, the window must be replaced. Refer to 757 AMM 56-11-01 as an accepted procedure. (l) 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, overheating, pitting corrosion or other surface damage, the lug must be replaced. Refer to SWPM 20-64-16 as an accepted procedure.(m) 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. Refer to SWPM 20-64-16 as an accepted procedure. (n) Make sure the screw has been aligned correctly. (o) A new o-ring is only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 for the correct screw, washer and o-ring. (p) Do step 2 to make sure the screw has been installed correctly and is a tight connection.

**FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD (SHEET 6 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 36 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  **(SHEET 1 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 37 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  **(SHEET 2 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 38 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD**  **(SHEET 3 OF 6)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 39 of 52 **BOEING SERVICE BULLETIN 757-30-0020**The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  at the J1, J4 and J5 connection. (a) 3 J1, J4, J5 Terminal Block Inspect 1 (b) 3

- Lug Inspect (c) 3 WIRE BUNDLE W2314 Wiring Inspect 3

- Cover Remove / Keep 2 to make sure it is a tight connection. (d) (e) (f) (g) 3

- Lug Inspect

not necessary if the lug is loose. (h) 3

- Cover Install (Kept)
**CAUTION:** DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW.
to 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. (i) (j) 3

- Screw Torque 3

to make sure the connection is tight. 3

- Lug Inspect not necessary if thelug cannot be tightened. 3

- Cover Install (Kept)

to make sure the screw is installedand there is no damage to terminal, lug or screw. 3

- Screw Remove 4

3

- Washer Remove 3

- O-ring Remove to make sure the terminal or lug is not damaged. (k) 3 J1, J4, J5 Terminal Inspect

(l) 3

- Lug Inspect

**FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD (SHEET 4 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 40 of 52 **BOEING SERVICE BULLETIN 757-30-0020 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP CAUTION:**  DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE WINDOW. to make sure lug isassembled to terminal with new, undamaged and correct hardware. (m) (n) 3

- Screw Install (New) 5

3

- Washer Install (New) (o) 3

- O-ring Install (New) to 25 to 30 inch pounds of torque. Refer to SWPM 20-64-16 as an accepted procedure. (p) 3

- Screw Torque

3

- Cover Install (Kept) (a) If the terminal block has melted, distorted or cracked, replace the windshield; refer to 757 AMM 56-11-01 as an accepted procedure. (b) If the terminal lug or cover has melted, replace the shipside terminal lug, refer to SWPM 20-64-16 ; and replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure. (c) 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. (d) 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. 4-The screw is cross threaded. (e) 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. (f) If the lug shows signs of arcing, blueing, overheating or melting, replace the lug, refer to SWPM 20-64- 16; and replace the windshield, refer to 757 AMM 56-11-01 as an accepted procedure. (g) If the lug is installed correctly, is tight, and is parallel to the terminal block, install the cover. No more work is necessary. (h) If the lug is loose, do step 3. (i) 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. (j) If the cross threaded screw can not be tightened, replace the window. Refer to 757 AMM 56-11-01 as an accepted procedure.

**FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD (SHEET 5 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 41 of 52 **BOEING SERVICE BULLETIN 757-30-0020 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (k) 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, overheating, pitting corrosion or other surface damage, the window must be replaced. Refer to 757 AMM 56-11-01 as an accepted procedure. (l) 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 overheating, pitting corrosion or other surface damage, the lug must be replaced. Refer to SWPM 20-64-16 as an accepted procedure.(m) 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. Refer to SWPM 20-64-16 as an accepted procedure. (n) Make sure the screw has been aligned correctly. (o) A new o-ring is only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 for the correct screw, washer and o-ring. (p) Do step 2 to make sure the screw has been installed correctly and is a tight connection.

**FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD (SHEET 6 OF 6)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 42 of 52 **BOEING SERVICE BULLETIN 757-30-0020 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. The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  to clear the new terminal. (a) - 233T8300-7 Bulb Seal Cut 1 (b)

- - Glareshield Identify 2

**FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 43 of 52 **BOEING SERVICE BULLETIN 757-30-0020 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (a) If the finish below the bulb seal is damaged, it must 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. (b) Part mark with service bulletin number before new windshield is installed. Refer to SOPM 20-50-10 as an accepted procedure.

**FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 44 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 45 of 52 **BOEING SERVICE BULLETIN 757-30-0020**The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG NOTE**  1 BMS 13-60, Type 1, Class 1, AWG 12 Wire 1

1 BMS 13-60, Type 1, Class 1, AWG 12 Wire 2 or optional BACS38K5C Tie Strap.

- BMS 13-54, Type 3, Class 1, Red Lacing Tape Red is for left channel separation. Refer to Standard Wiring PracticesManual SWPM 20-10-19 as an accepted procedure.Refer to SWPM 20-10-18 as an accepted procedure. 2 280N3355-10103 Sleeve 3
Refer to SWPM 20-64-18 as an accepted procedure. (a) 2 M39029/57-359 Socket Contact 4
Refer to SWPM 20-30-11 as an accepted procedure. 2 BACT12AC-12 Terminal Lug 5 (a) Isopropyl alcohol is applied to the installation tool and on the contact before installation of thecontact. Isopropyl alcohol is a lubricant that helps with installation of the contact in the connector.

**FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 46 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 47 of 52 **BOEING SERVICE BULLETIN 757-30-0020 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. The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **TASK STEP**  to clear the new terminal. (a) - 233T8300-8 Bulb Seal Cut 1 (b)

- - Glareshield Identify 2 (a) If the finish below the bulb seal is damaged, it must be sealed with chemical treatment and primer. Refer to Standard Overhaul Practices Manual SOPM 20-41-02 and SOPM 20-43- 03, if necessary.

**FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD (SHEET 1 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 48 of 52 **BOEING SERVICE BULLETIN 757-30-0020 MORE DATA**  **QTY IDENTIFICATION**  **NAME TASK**  **STEP** (b) Part mark with service bulletin number before new windshield is installed. Refer to SOPM 20-50-10 as an accepted procedure.

**FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 49 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD**  **(SHEET 1 OF 2)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 50 of 52 **BOEING SERVICE BULLETIN 757-30-0020**The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.
**MORE DATA QTY**  **IDENTIFICATION NAME**  **FLAG NOTE**  1 BMS 13-60, Type 1, Class 1, AWG 12 Wire 1

1 BMS 13-60, Type 1, Class 1, AWG 12 Wire 2 or optional BACS38K5F Tie Strap. BMS 13-54, Type 3, Class 1, Green Lacing Tape Green is for right channel separation. Refer to Standard Wiring PracticesManual SWPM 20-10-19 as an accepted procedure.Refer to SWPM 20-10-18 as an accepted procedure. 2 280N3355-10203 Sleeve 3
Refer to SWPM 20-64-18 as an accepted procedure. (a) 2 M39029/57-359 Socket Contact 4 Refer to SWPM 20-30-11 as an accepted procedure. 2 BACT12AC-12 Terminal Lug 5 (a) 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.

**FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD (SHEET 2 OF 2)** 

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 51 of 52 **BOEING SERVICE BULLETIN 757-30-0020 FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD**  **(SHEET 1 OF 1)**

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: July 19, 2006 757-30-0020 Revision 3 December 16, 2011 52 of 52 **BOEING SERVICE BULLETIN 757-30-0020**