Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Number: 757-30-0019

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

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ECCN: 9E991

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Unpublished Work - All Rights Reserved

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4.0
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BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 22

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 27

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 29

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . 35

FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 41

FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . . 47

FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 49

FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . . . . . . . . 51

FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . . 52

FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . 54

FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . . . . . . . 56

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BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGE
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 757-30-0019

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 the airplanes inspected in accordance with the original issue or Revision 1 of this

service bulletin.

No more work is necessary on the airplanes inspected in accordance with Revision 2 of this service bulletin.

No more work is necessary on the 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, added FAA AD 2010-15-01 and a changed a Standard Wiring Practices

Manual (SWPM) reference.

6. In Paragraph 2.A., Material - Price and Availability, updated kit price and availability.

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7. In Paragraph 2.C.1., Kit/Parts, added new windshield part numbers and serial numbers to the kit table.

8. In Paragraph 2.E., Special Tooling - Price and Availability, updated tool kit price.

9. In FIGURE 1 and FIGURE 2:

a. Removed circle notes 6 and 7 and changed the illustrations.

b. Step tables, changed the format and steps in the tables.

c. Footnotes, added AMM reference.

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

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, 2010

Revision 3: December 16, 2011

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BOEING SERVICE BULLETIN 757-30-0019
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Summary Number: 757-30-0019

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.

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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 a detailed 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

Federal Aviation Administration (FAA) Airworthiness Directive AD 2010-15-01 is related to this service bulletin.

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

Work Package Total Task Hours Elapsed Hours

Work Package 1 - Detailed Inspection of the Left 1.5 1.5

Windshield

Work Package 2 - Detailed Inspection of the Right 1.5 1.5

Windshield

Work Package 3 - Left Windshield Replacement and 8.5 4.75

Wiring Change

Work Package 4 - Right Windshield Replacement and 8.5 4.75

Wiring Change

MATERIAL INFORMATION

Boeing Supplied Kits/Parts

Refer to Paragraph 2.A., Material - Price and Availability.

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BLANK PAGE
Commercial 

Airplanes 757

Service Bulletin

SPECIAL ATTENTION

Number: 757-30-0019

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.

GROUP CONFIGURATION DESCRIPTION

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.

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 1.

2 -

Airplane Models:

757-200, 757-200CB, 757-200PF

Variable Number Group

NA002 - NA028 1

NA191 - NA199 1

NA201 - NA239 1

NA301 - NA305 1

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Variable Number Group

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 1

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

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BOEING SERVICE BULLETIN 757-30-0019
Variable Number Group

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

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

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BOEING SERVICE BULLETIN 757-30-0019
Variable Number Group

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

NT861 - NT862 1

NT881 - NT885 1

NT901 - NT916 1

NT971 - NT985 1

NU031 - NU038 1

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

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BOEING SERVICE BULLETIN 757-30-0019
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.

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 was 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.

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.

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BOEING SERVICE BULLETIN 757-30-0019
D. Description

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.

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.

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.

Group 1:

Affected Maintenance Zones

Model Zone

757-200, 757-200CB, 757- 211, 212

200PF

Group 2:

Affected Maintenance Zones

Model Zone

757-200PF 211, 212

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 .

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BOEING SERVICE BULLETIN 757-30-0019
Compliance Table:

Repeat Interval

(Whichever Occurs

Later)

Compliance Time

(Whichever Occurs First)

Condition Action

Terminating action for

this bulletin.

Replace with windshield that ----

uses pins and sockets for window heat power connection in

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 24 months

until windshield is replaced with windshield

that uses pins and

sockets for the window 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.

2. Inspect the window terminal

blocks, look for signs 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.

PPG Windshield that uses screws and lugs for

window heat power connection.

4. Inspect the terminal lug for

looseness.

5. Address the inspection

findings as described in Inspection Conditions 1 thru 4.

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BOEING SERVICE BULLETIN 757-30-0019
Compliance Table:

Repeat Interval

(Whichever Occurs

Later)

Compliance Time

(Whichever Occurs First)

Condition Action

Every 12,000 flight

hours or 48 months

until windshield is replaced with windshield

that uses pins and

sockets for window

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.

2. Inspect the window terminal

blocks, look for signs 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.

GKN Windshield that uses screws and lugs for

window heat power connection.

4. Inspect the terminal lug for

looseness.

5. Address the inspection

findings as described in Inspection Conditions 1 thru 4.

1. Repair or replace shipside Before further flight. ----

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. If the terminal lug has melted, replace the shipside terminal lug and windshield in accordance with Work Package 1,

step 2, or Work Package 2,

step 2; as applicable.

2. Discolored shipside

wire insulation.

3. Melted terminal lug.

4. Melted cover.

1. Replace windshield in accor- Before further flight. ----

dance 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.

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Compliance Table:

Repeat Interval

(Whichever Occurs

Later)

Compliance Time

(Whichever Occurs First)

Condition Action

1. Inspect the terminal for Before further flight. ----

looseness. If the cross threaded terminal is loose: torque the

terminal screw to 25-30 in-lb.

Inspection Condition 3 -

If the inspection reveals

evidence the window

heat power connection is

cross threaded. 2. Re-inspect terminal lug for

looseness.

3. If terminal lug is still loose

replace windshield in accordance with Work Package 1,

step 2, or Work Package 2,

step 2; as applicable.

Within 150 days or 500 flight ----

hours 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.

1. Torque the terminal screw Before further flight. ----

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 still loose

then disassemble, inspect and

reassemble the electrical connection in accordance with

Work Package 1, step 2 or

Work Package 2, step 2; as

applicable.

Within 150 days or 500 flight ----

hours, after the reassembly

of the windshield heat power

connection. (a)

Do a detailed inspection in accordance with Work Package

1, step 2 or Work Package 2,

step 2; as applicable.

Window heat power connection is reassembled

(on windshields that uses

screws and lugs for window heat power connection).

OR

If 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 bulletin should be

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Compliance Table:

Repeat Interval

(Whichever Occurs

Later)

Compliance Time

(Whichever Occurs First)

Condition Action

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.

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

— 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

Number of Per- Task-Hours Elapsed Hours

sons

Task

FIGURE 1 1 1.50 1.50

Total per Windshield 1.50 1.50

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Work Package 2 - Inspection of the Right Windshield

Number of Per- Task-Hours Elapsed Hours

sons

Task

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

Number of Per- Task-Hours Elapsed Hours

sons

Task

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

FIGURE 4 and FIGURE 5 - 1 0.50 0.50

Change the Wiring

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

Number of Per- Task-Hours Elapsed Hours

sons

Task

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

FIGURE 7 and FIGURE 8 - 1 0.50 0.50

Change the Wiring

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 4.75

H. Weight and Balance Changes

None

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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

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

Publication Chapter-Section

757 Maintenance Manual 30-41, 56-11

757 Wiring Diagram Manual 30-41

757 Illustrated Parts Catalog 56-11

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.

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BOEING SERVICE BULLETIN 757-30-0019
L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability

information.

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BOEING SERVICE BULLETIN 757-30-0019
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BOEING SERVICE BULLETIN 757-30-0019

BLANK PAGE
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 Service Bulletin (US

Dollars)

ROLT as of the

Revision 03 date

of this Service

Bulletin (Calendar

Days)

Kit Number Name

Top Kit - Left Windshield - PPG with hy- 130 $19,687.00

drophobic coating

012N8926-7

Top Kit - Right Windshield - PPG with hy- 130 $19,687.00

drophobic coating

012N8926-8

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 (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

Top Kit - Left Windshield, PPG

with Hydrophobic coating

012N8926-7 . -

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BOEING SERVICE BULLETIN 757-30-0019
Kit 012N8926

New Part Number QTY Name Notes

-8 -7

Top Kit - Right Windshield, PPG

with Hydrophobic coating

012N8926-8 - .

(a) (b) (c) (d)

(f) (h) (j) (l)

(m)

PPG Left Windshield Assembly

with Hydrophobic coating

141W7400-43 . 1

(a) (b) (c) (e)

(g) (i) (k) (l)

(m)

PPG Right Windshield Assembly

with Hydrophobic coating

141W7400-44 1 .

Wire Kit - Flight Deck Window

Heat

280N3355-1 . 1

Wire Kit - Flight Deck Window

Heat

280N3355-2 1 .

(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.

(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 thru 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.

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BOEING SERVICE BULLETIN 757-30-0019
Kit 280N3355

New Part Number QTY Name Notes

-102 -101 -2 -1

Wire Kit - Flight Deck

Window Heat

280N3355-1 . . . -

Wire Kit - Flight Deck

Window Heat

280N3355-2 . . - .

Kit, Wire Bundle

W2304

280N3355-101 . - . 1

280N3355-102 - . 1 . Kit, Wire BundleW2314

BMS 13-52 Expandable

Sleeve

280N3355-10103 . 1 . .

BMS 13-52 Expandable

Sleeve

280N3355-10203 1 . . .

Wire Identified W2304- (a)

0001-12

- . 1 . .

Wire Identified W2304- (b)

0002-12

- . 1 . .

Wire Identified W2314- (a)

0001-12

- 1 . . .

Wire Identified W2314- (b)

0002-12

- 1 . . .

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.

2. Parts and Materials Supplied by the Operator:

Part Number / QTY Name Notes

Specification

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.

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Part Number / QTY Name Notes

Specification

(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.

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.

Existing Part QTY Name New Part Number Notes

Number

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.

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

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BOEING SERVICE BULLETIN 757-30-0019
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 Service Bulletin (US

Dollars)

Tool Kit Number Name

A56001-2 (part of Windshield Handling Sling $766.00

Sling Set A56001-

15)

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.

Tool Kit Number Name

A56001-2 (part of Windshield Handling Sling

Sling Set A56001-15)

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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.

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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 circuit breaker shown below and attach a DO-NOT-CLOSE tag to it:

Location Panel / Name Circuit Breaker

Position

Airplane

Group

1 P70 / C13 WINDOW HEATER 1L C391

2 P31 / A05 WINDOW HEATER 1L C391

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 circuit breaker shown below:

Location Panel / Name Circuit Breaker

Position

Airplane

Group

1 P70 / C13 WINDOW HEATER 1L C391

2 P31 / A05 WINDOW HEATER 1L C391

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:

Location Panel / Name Circuit Breaker

Position

P37 / J2 WINDOW HEATER 1R C392

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 the circuit breaker shown below:

Location Panel / Name Circuit Breaker

Position

P37 / J2 WINDOW HEATER 1R C392

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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 to it:

Location Panel / Name Circuit Breaker

Position

Airplane

Group

1 P70 / C13 WINDOW HEATER 1L C391

2 P31 / A05 WINDOW HEATER 1L C391

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. 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:

Description Part Number Part of Top Kit

PPG with Hydrophobic Coating 141W7400-43 012N8926-7

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

Location Panel / Name Circuit Breaker

Position

Airplane

Group

1 P70 / C13 WINDOW HEATER 1L C391

2 P31 / A05 WINDOW HEATER 1L C391

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.

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:

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Location Panel / Name Circuit Breaker

Position

P37 / J2 WINDOW HEATER 1R C392

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. 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:

Description Part Number Part of Top Kit

PPG with Hydrophobic Coating 141W7400-44 012N8926-8

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

Location Panel / Name Circuit Breaker

Position

P37 / J2 WINDOW HEATER 1R C392

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.

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FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

(SHEET 1 OF 6)

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FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN 757-30-0019
FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

(SHEET 3 OF 6)

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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

at the J1, J4 and J5

connection. (a)

1 Inspect Terminal Block J1, J4, J5 3

Inspect Lug - 3 (b)

Inspect Wiring WIRE BUNDLE W2304 3 (c)

2 Remove / Keep Cover - 3

to make sure it is a

tight connection. (d)

(e) (f) (g)

Inspect Lug - 3

not necessary if the

lug is loose. (h)

Install (Kept) Cover - 3

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 Torque Screw - 3

to make sure the

connection is tight.

Inspect Lug - 3

not necessary if the

lug cannot be tightened.

Install (Kept) Cover - 3

to make sure the

screw is installed

and there is no damage to terminal, lug

or screw.

4 Remove Screw - 3

Remove Washer - 3

Remove O-ring - 3

to make sure the

terminal or lug is not

damaged. (k)

Inspect Terminal J1, J4, J5 3

Inspect Lug - 3 (l)

FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

(SHEET 4 OF 6)

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BOEING SERVICE BULLETIN 757-30-0019
STEP TASK NAME IDENTIFICATION QTY MORE DATA

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 is

assembled to terminal with new, undamaged and correct

hardware. (m) (n)

5 Install (New) Screw - 3

Install (New) Washer - 3

Install (New) O-ring - 3 (o)

to 25 to 30 inch

pounds of torque.

Refer to SWPM 20-

64-16 as an accepted procedure. (p)

Torque Screw - 3

Install (Kept) Cover - 3

(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)

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BOEING SERVICE BULLETIN 757-30-0019
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(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)

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BOEING SERVICE BULLETIN 757-30-0019
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

(SHEET 1 OF 6)

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BOEING SERVICE BULLETIN 757-30-0019
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

(SHEET 2 OF 6)

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BOEING SERVICE BULLETIN 757-30-0019
FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

(SHEET 3 OF 6)

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Original Issue: July 19, 2006

Revision 3 December 16, 2011 757-30-0019

43 of 56

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

at the J1, J4 and J5

connection. (a)

1 Inspect Terminal Block J1, J4, J5 3

Inspect Lug - 3 (b)

Inspect Wiring WIRE BUNDLE W2314 3 (c)

2 Remove / Keep Cover - 3

to make sure it is a

tight connection. (d)

(e) (f) (g)

Inspect Lug - 3

not necessary if the

lug is loose. (h)

Install (Kept) Cover - 3

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 Torque Screw - 3

to make sure the

connection is tight.

Inspect Lug - 3

not necessary if the

lug cannot be tightened.

Install (Kept) Cover - 3

to make sure the

screw is installed

and there is no damage to terminal, lug

or screw.

4 Remove Screw - 3

Remove Washer - 3

Remove O-ring - 3

to make sure the

terminal or lug is not

damaged. (k)

Inspect Terminal J1, J4, J5 3

Inspect Lug - 3 (l)

FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

(SHEET 4 OF 6)

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44 of 56

BOEING SERVICE BULLETIN 757-30-0019
STEP TASK NAME IDENTIFICATION QTY MORE DATA

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 is

assembled to terminal with new, undamaged and correct

hardware. (m) (n)

5 Install (New) Screw - 3

Install (New) Washer - 3

Install (New) O-ring - 3 (o)

to 25 to 30 inch

pounds of torque.

Refer to SWPM 20-

64-16 as an accepted procedure. (p)

Torque Screw - 3

Install (Kept) Cover - 3

(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)

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BOEING SERVICE BULLETIN 757-30-0019
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(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)

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BOEING SERVICE BULLETIN 757-30-0019
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for this 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.

to clear the new terminal. (a)

1 Cut Bulb Seal 233T8300-7 -

2 Identify Glareshield - - (b)

FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-30-0019
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(a) If the finish below the bulb seal is damaged, it will need to be sealed with chemical treatment and primer.

Refer to 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)

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BOEING SERVICE BULLETIN 757-30-0019
FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-30-0019
The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

BMS 13-60, Type 1, 1

Class 1, AWG 12

1 Wire

BMS 13-60, Type 1, 1

Class 1, AWG 12

2 Wire

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.

BMS 13-54, Type 3, -

Class 1, Red

Lacing Tape

Refer to SWPM 20-10-18 as an accepted procedure.3 Sleeve 280N3355-10103 2

Refer to SWPM 20-64-18 as an accepted procedure. (a)4 Socket Contact M39029/57-359 2

Refer to SWPM 20-30-11 as an accepted procedure.5 Terminal Lug BACT12AC-12 2

(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 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 757-30-0019
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

Revision 3 December 16, 2011 757-30-0019

51 of 56

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

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.

to clear the new terminal. (a)

1 Cut Bulb Seal 233T8300-8 1

2 Identify Glareshield - - (b)

(a) If the finish below the bulb seal is damaged, it will need to be sealed with chemical treatment and primer.

Refer to SOPM 20-41-02 and SOPM 20-43-03 as accepted procedures.

FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 757-30-0019
STEP TASK NAME IDENTIFICATION QTY MORE DATA

(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)

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BOEING SERVICE BULLETIN 757-30-0019
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

Revision 3 December 16, 2011 757-30-0019

54 of 56

BOEING SERVICE BULLETIN 757-30-0019
The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME IDENTIFICATION QTY MORE DATA

NOTE

BMS 13-60, Type 1, 1

Class 1, AWG 12

1 Wire

BMS 13-60, Type 1, 1

Class 1, AWG 12

2 Wire

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.

BMS 13-54, Type 3, -

Class 1, Green

Lacing Tape

Refer to SWPM 20-10-18 as an accepted procedure.3 Sleeve 280N3355-10203 2

Refer to SWPM 20-64-18 as an accepted procedure. (a)4 Socket Contact M39029/57-359 2

Refer to SWPM 20-30-11 as an accepted procedure.5 Terminal Lug BACT12AC-12 2

(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)

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BOEING SERVICE BULLETIN 757-30-0019
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

Revision 3 December 16, 2011 757-30-0019

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BOEING SERVICE BULLETIN 757-30-0019