July 19, 2006

Revision 2: March 31, 2010 757-30-0020

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 48

Commercial

Airplane

Group 757

SPECIAL ATTENTION

Service Bulletin

Number: 757-30-0020

Date: July 19, 2006

Revision 2: March 31, 2010

ATA System: 3041 5611

SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield 

Inspection and Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2006 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable 

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third 

parties. Treatment of the document and the information it contains is governed by contract with Boeing. For 

more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, 

MD-11, MD-80, MD-90, the Boeing logo and the Boeing livery are among the trademarks owned by Boeing or 

its subsidiaries. No intellectual property license (express or implied) is granted in connection with this document 

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 Table of Contents

July 19, 2006

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BOEING SERVICE BULLETIN 757-30-0020

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 24

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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. . . . . . . . . . . . . . . . . . . . . . . . 36

FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD . . . . . . . . . . . . . . . . . . 41

FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . 42

FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD . . . . . . . . 44

FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD . . . . . . . . . . . . . . . . . . 45

FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD 46

FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD . . . . . . . 48
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Commercial

Airplanes 757

SPECIAL ATTENTION

Service Bulletin

Number: 757-30-0020 Revision Transmittal Sheet

Original Issue: July 19, 2006

Revision 2: March 31, 2010

ATA System: 3041 5611

SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield 

Inspection and Replacement

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes changed as shown in the original issue and Revision 1 of this service 

bulletin.

Operators that have not done the terminating action in the compliance of this service bulletin will now need to 

also inspect the J1 and J4 windshield lugs and terminals.

REASON FOR REVISION

This revision is sent to tell operators that have not done the terminating action in the compliance of this service 

bulletin that they will need to also inspect the J1 and J4 windshield lugs and terminals.

These sections were changed:

1. Summary Background, Planning Information 1.D., Reason and 1.J.1., Existing Data, Service Related 

Problem (SRP) 757-SRP-30-0031 has been added.

2. Summary Action and Planning Information 1.D., Description, have been changed to add the inspection of 

the J1 and J4 lugs and terminals.

3. Summary Compliance and Planning Information 1.E., Compliance, a statement has been added to say the 

Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this 

service bulletin.

4. In Planning Information 1.E., Compliance, the compliance table has been changed to add the inspection 

of windshield J1 and J4 lugs and terminals.

5. In Planning Information 1.G., Manpower, manpower tables have been changed to add the time for 

inspection of the J1 and J4 lugs and terminals.

6. In Planning Information 1.J.1., Existing Data, Standard Wiring Practices Manual (SWPM) reference 20-64-

16 and Illustrated Parts Catalog (IPC) reference 30-41-52 have been added.
 

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7. In Planning Information 1.K.2., Publications Affected, Damage Tolerance Based Structural Inspection 

evaluation Statement has been added.

8. In the Material Information 2.C.1., the kit table has been changed to show that the 280N3355-1 wire kit 

contains the -101 kit and the 280N3355-2 wire kit contains the -102 kit.

9. In the Work Instructions 3.B., step 3 of Work Packages 1 and 2 has been changed to add new compliance 

time thresholds for windshield inspections.

10. In Figure 1 and Figure 2 the illustrations have been changed to add the inspection of the J1 and J4 lugs 

and terminals.

11. In Figure 1 and Figure 2 new illustrations have been added to show the correct alignment of the lug on the 

terminal.

12. In Figure 1 and Figure 2, step 2, the step table note has changed to show another cause of a loose terminal. 

The Standard Overhaul Practices Manual (SOPM) reference 20-43-03 has been changed to Standard 

Wiring Practices Manual (SWPM) reference 20-64-16 and Illustrated Parts Catalog (IPC) reference 30-41-

52 has been added. New steps have been added to give instructions to inspect the screw if it cannot be 

tightened in step 3.

13. Figure 6, in the illustration, circle note 2 has been moved to point to an area near the bulb seal. This is the 

area where the part mark can be applied.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity 

paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location 

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: July 19, 2006

Revision 1: December 19, 2007

Revision 2:
Original Issue: July 19, 2006

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Commercial

Airplanes 757

SPECIAL ATTENTION

Service Bulletin

Number: 757-30-0020 Summary

Original Issue: July 19, 2006

Revision 2: March 31, 2010

ATA System: 3041 5611

SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield 

Inspection and Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

None

BACKGROUND

This service bulletin gives instructions to do an inspection of the electrical connections on the left and the right 

windshields. Instructions are also given to replace the windshields and make changes to their related wire 

bundles. A new windshield design is available that uses a different electrical connection.

Boeing received nine reports from eight operators of electrical arcs at the terminal blocks of the flight 

compartment windows. More than one of these reports included data to show that the results of the arcs were 

open flame incidents. One operator found an indication of damage at a terminal and tightened a loose 

connection. The terminal had internal damage that could not be seen. Less than six months after the 

connection was tightened there was a report from the operator of an open flame incident on the same 

windshield.

The electrical connections on the windows are made with lugs that are attached with screws. The windshield 

is the number 1 window in the flight compartment. All of the windows in the flight compartment are electrically 

heated. The windshield gets a much larger electrical load. 

An investigation found that the cause of the electrical arcs is loose terminal connections. A loose connection 

increases the heat at the terminal which can cause damage to the internal solder joint. Damaged solder joints 

are the primary cause for the electrical arcs. The primary causes of loose connections are the incorrect torque 

of the screw or an incorrectly installed screw.

The inspection given in this service bulletin is to look for damage or a loose electrical connection on the 

windshield. If there are indications of electrical arcs or damage to the electrical connection, the windshield is 

replaced. If there is a loose electrical connection, the correct torque is applied to tighten it. If a connection 

cannot be tightened to the correct torque, the windshield is replaced. When a windshield with an electrical 

connection that uses pins and sockets is installed, the related wire bundle on the airplane is changed.
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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.

ACTION (PRR 54530-265S)

In the flight compartment, do an inspection of the J1, J4 and J5 lugs and terminals on the left and the right 

windshields. Replace windshields that use screws and lugs for the electrical connections with a windshield that 

uses pins and sockets for the electrical connections. Cut the bulb seal to give clearance for terminals on the 

new windshield. Change the related wire bundle.

EFFECTIVITY

All 757-300 Airplanes. Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes. 

COMPLIANCE

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service 

bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin 

mandatory.

See Service Bulletin Paragraph 1.E. for compliance information.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

MATERIAL INFORMATION

Boeing Supplied Kits/Parts

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

Work Package Total Task Hours Elapsed Hours

Work Package 1 - Inspection of the Left Windshield 1.5 1.5

Work Package 2 - Inspection of the Right Windshield 1.5 1.5

Work Package 3 - Left Windshield Replacement and 

Wiring Change 

8.5 4.75

Work Package 4 - Right Windshield Replacement and 

Wiring Change 

8.5 4.75
 

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BOEING SERVICE BULLETIN 757-30-0020

485171

CUT THE BULB SEAL AND

CUT THE BULB SEAL AND

WORK PACKAGE 1:

INSPECT THE LEFT WINDSHIELD

REPLACE THE LEFT WINDSHIELD.

CHANGE THE RELATED WIRING.

WORK PACKAGE 3:

WORK PACKAGE 2:

INSPECT THE RIGHT WINDSHIELD

CHANGE THE RELATED WIRING.

REPLACE THE RIGHT WINDSHIELD.

WORK PACKAGE 4:
 

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BOEING SERVICE BULLETIN 757-30-0020

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Commercial

Airplanes 757

SPECIAL ATTENTION

Service Bulletin

Number: 757-30-0020

Original Issue: July 19, 2006

Revision 2: March 31, 2010

ATA System: 3041 5611

SUBJECT: ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Icing - Windshield 

Inspection and Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D624N001 Part 3 for Airplane Variable Number, Line 

Number, and Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent 

production airplanes. Refer to PRR 54530-265S for data about this change.

Airplane models:

757-300

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

ARKIA ISRAELI AIRLINES (ARK)

1 NU731–NU732

BOEING CAPITAL CORPORATION (ZMF)

1 NL006 NL008 NL016–NL017

CONDOR (CDF)

1 NU701–NU705 NU721–NU728

CONTINENTAL AIRLINES (CAL)

1 NL007 NL009–NL015 NL101–NL109

GROUP CONFIGURATION DESCRIPTION

1 - Airplanes with windshields that use screw and 

lug electrical connections.
 

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BOEING SERVICE BULLETIN 757-30-0020

ICELANDAIR (ICE)

1 NL141

NORTHWEST AIRLINES (NWA)

1 NL601–NL616

THOMAS COOK AIRLINES UK (JMA)

1 NL001–NL002

IDENTIFICATION BY VARIABLE NUMBER

2. Spares Affected

Examine your spares supply for the parts or components identified in Paragraph 2.C., Parts 

Necessary for Each Airplane. If any parts or components are found, refer to Paragraph 2.C. for 

the recommended use.

B. Concurrent Requirements

None

C. Reason

This service bulletin gives instructions to do an inspection of the electrical connections on the left and 

the right windshields. Instructions are also given to replace the windshields and make changes to their 

related wire bundles. A new windshield design is available that uses a different electrical connection.

Boeing received nine reports from eight operators of electrical arcs at the terminal blocks of the flight 

compartment windows. More than one of these reports included data to show that the results of the 

arcs were open flame incidents. One operator found an indication of damage at a terminal and 

tightened a loose connection. The terminal had internal damage that could not be seen. Less than 

six months after the connection was tightened there was a report from the operator of an open flame 

incident on the same windshield.

The electrical connections on the windows are made with lugs that are attached with screws. The 

windshield is the number 1 window in the flight compartment. All of the windows in the flight 

compartment are electrically heated. The windshield gets a much larger electrical load. 

Variable Group

NL001–NL002 1

NL006–NL017 1

NL101–NL109 1

NL141 1

NL601–NL616 1

NU701–NU705 1

NU721–NU728 1

NU731–NU732 1
 

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BOEING SERVICE BULLETIN 757-30-0020

An investigation found that the cause of the electrical arcs is loose terminal connections. A loose 

connection increases the heat at the terminal which can cause damage to the internal solder joint. 

Damaged solder joints are the primary cause for the electrical arcs. The primary causes of loose 

connections are the incorrect torque of the screw or an incorrectly installed screw.

The inspection given in this service bulletin is to look for damage or a loose electrical connection on 

the windshield. If there are indications of electrical arcs or damage to the electrical connection, the 

windshield is replaced. If there is a loose electrical connection, the correct torque is applied to tighten 

it. If a connection cannot be tightened to the correct torque, the windshield is replaced. When a 

windshield with an electrical connection that uses pins and sockets is installed, the related wire bundle 

on the airplane is changed.

When the changes given in this bulletin are done, the windshields will have better electrical 

connections. The new connections are made with pins and sockets. The pin and socket connections 

will prevent the risk of electrical arcs as a result of loose connections.

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.

Revision 2 is 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.

D. Description

In the flight compartment, an inspection is done of the left and the right windshields. A windshield that 

uses pin and socket electrical connections is installed. The bulb seal is cut to give clearance for 

terminals that are on the new windshield. When a windshield that uses the pin and socket electrical 

connections is installed, the related wire bundle is also changed.

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 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.
 

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BOEING SERVICE BULLETIN 757-30-0020

E. Compliance

The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to 

this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in 

this service bulletin mandatory.

Compliance Table:

Condition Action

Compliance Time

(Whichever Occurs First)

Repeat Interval 

(Not to Exceed)

Windshield that uses 

screws and lugs for window 

heat power connection.

Replace with windshield 

that uses pins and 

sockets for window heat 

power connection in 

accordance with 

Accomplishment 

Instructions Work 

Packages 3 and 4.

 ---- Terminating action 

for this bulletin.

PPG Windshield that uses 

screws and lugs for window 

heat power connection.

Do the actions that follow 

for J1, J4 and J5 window 

heat power connections:

1. Inspect the shipside 

wiring and terminal lug 

(including cap) look for 

signs of melted or 

discolored insulation.

2. Inspect the window 

terminal blocks, look for 

signs of melting or 

distortion.

3. Inspect the window 

heat power connection for 

evidence of cross 

threading by making sure 

the terminal lug is parallel 

with the window terminal 

block.

4. Inspect the terminal lug 

for looseness.

5. Address the inspection 

findings as described in 

Inspection Conditions 1 

thru 4.

Within 500 flight hours or 

150 days, whichever occurs 

earlier, after the date of 

Revision 2 to the service 

bulletin.

Every 6000 flight 

hours or 24 months 

until windshield is 

replaced with 

windshield that 

used pins and 

sockets for window 

heat power 

connection in 

accordance with 

Accomplishment 

Instructions Work 

Packages 3 and 4.
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GKN Windshield that uses 

screws and lugs for window 

heat power connection.

Do the actions that follow 

for J1, J4 and J5 window 

heat power connections:

1. Inspect the shipside 

wiring and terminal lug 

(including cap) look for 

signs of melted or 

discolored insulation.

2. Inspect the window 

terminal blocks, look for 

signs of melting or 

distortion.

3. Inspect the window 

heat power connection for 

evidence of cross 

threading by making sure 

the terminal lug is parallel 

with the window terminal 

block.

4. Inspect the terminal lug 

for looseness.

5. Address the inspection 

findings as described in 

Inspection Conditions 1 

thru 4.

Within 500 flight hours or 

150 days, whichever occurs 

earlier, after the date of 

Revision 2 to the service 

bulletin.

Every 12,000 flight 

hours or 48 months 

until windshield is 

replaced with 

windshield that 

used pins and 

sockets for window 

heat power 

connection in 

accordance with 

Accomplishment 

Instructions Work 

Packages 3 and 4.

Inspection Condition 1 - If 

the inspection reveals one 

or more signs of the 

following:

1. Melted shipside wire 

insulation.

2. Discolored shipside wire 

insulation.

3. Melted terminal lug.

4. Melted cap.

1. Repair or replace 

shipside wiring as 

necessary. Refer to 

Standard Wiring Practices 

Manual SWPM 20-10-13 

as an accepted 

procedure.

2. If the terminal lug has 

melted replace the 

shipside terminal lug and 

windshield in accordance 

with Work Package 1, 

step 3. Work Package 2, 

step 3.

Before further flight. ----

Compliance Table:

Condition Action

Compliance Time

(Whichever Occurs First)

Repeat Interval 

(Not to Exceed)
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Inspection Condition 2 - If 

the inspection reveals one 

or more signs of the 

following:

1. Melted window terminal 

block.

2. Distorted or cracked 

window terminal block.

1. Replace windshield in 

accordance with Work 

Package 1, step 3. and 

Work Package 2, step 3.

Before further flight. ----

Inspection Condition 3 - If 

the inspection reveals 

evidence that the window 

heat power connection is 

cross threaded.

1. Inspect the terminal for 

looseness. If the cross 

threaded terminal is loose: 

torque the terminal screw 

to 25-30 in-lb.

2. Re-inspect terminal lug 

for looseness.

3. If terminal lug is still 

loose replace windshield 

in accordance with Work 

Package 1, step 3. and 

Work Package 2. step 3.

Before further flight. ----

 

 

4. If terminal lug is tight, 

replace windshield in 

accordance with Work 

Package 1, step 3. and 

Work Package 2. step 3.

Within 150 days or 500 flight 

hours, whichever occurs 

earlier after the inspection.

 ----

Inspection Condition 4 - If 

the inspection reveals the 

terminal lug is loose.

1. Torque the terminal 

screw to 25-30 in-lb.

2. Re-inspect terminal lug 

for looseness.

3. If terminal lug is still 

loose.

Before further flight. ----

Compliance Table:

Condition Action

Compliance Time

(Whichever Occurs First)

Repeat Interval 

(Not to Exceed)
 

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BOEING SERVICE BULLETIN 757-30-0020

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes 

specified in this service bulletin comply with the applicable regulations and are FAA approved, as well 

as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/

JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval 

were based on the airplane in its original Boeing delivery configuration or as modified by other 

approved Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected 

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency 

approval before incorporating this service bulletin.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this inspection or change one 

window for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust 

the estimate with operator task-hour data if necessary. The estimate does not include lost time. 

These are some examples of lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

If the windshield is replaced 

with same type windshield 

that uses screws and lugs 

for window heat power 

connection.

OR

Window heat power 

connection is reassembled 

(on windshields that use 

screws and lugs for window 

heat power connection).

Do a detailed inspection in 

accordance with 

Accomplishment 

Instructions Work 

Package 1, step 2. and 

Work Package 2, step 2.

Within 150 days or 500 flight 

hours, whichever occurs 

earlier after installation of 

the same windshield type 

(a).

 ----

(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 

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.

Compliance Table:

Condition Action

Compliance Time

(Whichever Occurs First)

Repeat Interval 

(Not to Exceed)
 

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— Time to find the tools.

H. Weight and Balance Changes

None

Work Package 1 - Inspection of the Left Windshield

Task

Number of 

Persons Task-Hours Elapsed Hours

Figure 1 1 1.50 1.50

Total per Windshield 1.50 1.50

Work Package 2 - Inspection of the RIght Windshield

Task

Number of 

Persons Task-Hours Elapsed Hours

Figure 2 1 1.50 1.50

Total per Windshield 1.50 1.50

Work Package 3 - Replacement of the Left Windshield and Changes to the Related Wiring

Task

Number of 

Persons Task-Hours Elapsed Hours

Access 2 1.0 0.50

Remove the Left Windshield 2 2.5 1.25

Figure 3 - Cut the Bulb Seal 1 0.25 0.25

Figures 4 and 5 - Change the 

Wiring

1 0.50 0.50

Install the Left Windshield 2 3.0 1.5

Tests 1 0.25 0.25

Close 2 1.0 0.50

Total per Windshield 8.5 4.75

Work Package 4 - Replacement of the Right Windshield and Changes to the Related Wiring

Task

Number of 

Persons Task-Hours Elapsed Hours

Access 2 1.0 0.50

Remove the Right Windshield 2 2.5 1.25

Figure 6 - Cut the Bulb Seal 1 0.25 0.25

Figures 7 and 8 - Change the 

Wiring

1 0.50 0.50

Install the Right Windshield 2 3.0 1.5

Tests 1 0.25 0.25

Close 2 1.0 0.50

Total per Windshield 8.5 4.75
 

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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. 757 Aircraft Maintenance Manual (AMM) 30-41-00, 56-11-01

d. Wiring Diagram 30-41-11, 30-41-12

e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-13, 20-10-18, 

20-10-19, 20-20-00, 20-30-11, 20-63-19, 20-64-16

f. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-03, 20-50-10

g. 757 Illustrated Parts Catalog (IPC) 30-41-52

h. Boeing Service Bulletin 767-56-0012

2. Data supplied with this Service Bulletin:

None

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

None

K. Publications Affected

1. Publications

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue 

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the 

Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not 

necessary.

Publication Chapter-Section

757 Maintenance Manual 30-41, 56-11

757 Wiring Diagram Manual 30-41

757 Illustrated Parts Catalog 56-11
 

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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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2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown 

below. Kit availability is shown in the Reorder Lead Time (ROLT). ROLT is calculated from the date 

Boeing gets the purchase order.

The kits are subject to the terms and conditions of the Boeing standard purchase order 

acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in 

United States dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of the methods that follow: 

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

Kit Number Name

ROLT 

(Weeks)

Unit Price thru

Dec 31/07

012N8926-13 Top Kit - Left Windshield - PPG with 

hydrophobic coating

19 $16,480.00

012N8926-14 Top Kit - Right Windshield - PPG 

with hydrophobic coating

19 $16,480.00
 

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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 

New Part 

Number Name Notes -14 -13

012N8926-13 . - Top Kit - Left Windshield, PPG with 

Hydrophobic coating

012N8926-14 - . Top Kit - Right Windshield, PPG with 

Hydrophobic coating

141W7400-43 . 1 PPG Windshield Assembly - Left, with 

Hydrophobic coating

(a) (b) 

(c) (d) (f) 

(h) (j)

141W7400-44 1 . PPG Windshield Assembly - Right, with 

Hydrophobic coating

(a) (b) 

(c) (e) 

(g) (i) (j)

280N3355-1 . 1 Wire Kit - Flight Deck Window Heat - Wire 

Assembly W2304

280N3355-2 1 . Wire Kit - Flight Deck Window Heat - Wire 

Assembly W2314

(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 with 

serial numbers 04001Hxxxx through 05365Hxxxx.

(e) As an option operators can install Right Windshield part number 141T4801-60 with 

serial numbers 04001Hxxxx through 05365Hxxxx.

(f) As an option operators can install Left Windshield part number 141W7400-31 or 

141W7400-33 with serial numbers 04001Hxxxx through 05365Hxxxx.

(g) As an option operators can install Right Windshield part number 141W7400-32 or 

141W7400-34 with serial numbers 04001Hxxxx through 05365Hxxxx.

(h) As an option operators can install Left Windshield part number 141W7400-35 or 

141W7400-41.

(i) As an option operators can install Right Windshield part number 141W7400-36 or 

141W7400-42.

(J) PPG Aerospace - Transparencies Div Glass (V53117)

 P.O. Box 2200

 1719 U.S. Highway 72 East 

 Huntsville, AL 35811-9660
 

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Kit 280N3355 

New Part 

Number

QTY

-102 -101 -2 -1 Name Notes

280N3355-1 . . . - Wire Kit - Flight Deck Window 

Heat

280N3355-2 . . - . Wire Kit - Flight Deck Window 

Heat

280N3355-101 . - . 1 Kit, Wire Bundle

W2304

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

W2314

280N3355-10103 . 1 . . BMS 13-52 Expandable Sleeve

280N3355-10203 1 . . . BMS 13-52 Expandable Sleeve

- . 1 . . Wire Identified W2304-0001-12 (a)

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

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

- 1 . . . Wire Identified W2314-0002-12 (b)

BACT12AC-12 3 3 . . Terminal Lug (c)

M39029/57-359 3 3 . . Socket Contact (c)

(a) BMS 13-60, Type 1, Class 1, AWG 12, length 66 inches

(b) BMS 13-60, Type 1, Class 1, AWG 12, length 33 inches

(c) There are more parts than are necessary.
 

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2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the 

number of parts changed on each airplane.

4. Parts Removed and Not Replaced:

None

D. Parts Necessary to Change Spares

None

Part Number / 

Specification QTY Name Notes

BMS 13-54 10 feet Lacing Tape, Red (a) (b) (c) 

BMS 13-54 10 feet Lacing Tape, Green (a) (b) (d)

(a) Type 3, Class 1

(b) Gudebrod Incorporated (V82110)

 Griffith Towers 

 PO Box 357

 Pottstown, PA 19464

(c) BACS38K5C, red Tie Strap is optional. See the Qualified Products List at 

the end of the Boeing Material Specification (BMS) for the supplier data.

(d) BACS38K5F, green Tie Strap is optional. See the Qualified Products List 

at the end of the Boeing Material Specification (BMS) for the supplier data.

Existing Part 

Number QTY Name New Part Number Notes

233N8300-( ) 1 Glareshield - (a) (b)

(a) Make the change given in this service bulletin.

(b) There is no equivalent Boeing part number for the changed part. Identify on 

the part that the change given in this service bulletin was made.
 

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E. Special Tooling - Price and Availability

Boeing can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this Service 

Bulletin. Send a Purchase Order to the Director of Spares. Give this service bulletin number and the 

date the tools will be used.

The kits are subject to the terms and conditions of the Boeing standard purchase order 

acknowledgement. After the Price date, new price data is applicable. Prices are in United States 

dollars. Terms: Net 30 days.

Reference this service bulletin number and submit purchase order by one of the methods that follow:

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

(Service Bulletin 757-30-0020)

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.

Purchase Data:

Tool Kit Number Name

Unit Price

 thru Dec 31/07

A56001-2 (part of Sling Set

A56001-15)

Windshield Handling Sling $625.00

Tool Kit Number Name

A56001-2 (part of 

Sling Set A56001-15)

Windshield Handling Sling
 

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BLANK PAGE
 

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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED

MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES

CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE

SPARKS OR OTHER ELECTRICAL DAMAGE.

NOTE:

1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for 

definition of the acronyms.

2. Obey all of the warnings and cautions given in the specified manual sections.

3. The work instructions are divided into work packages. Task-Hours and Elapsed-Hours 

for each package are given in Paragraph 1.G., Manpower. You can do each work 

package independently.

4. Unless shown differently, these dimensions and tolerances are used:

— Linear dimensions are in inches

— Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, 

Chapter 51.

5. Refer to Standard Wiring Practices Manual SWPM 20-10-11 and SWPM 20-10-12 for 

the wire installation procedures.

6. A Detailed Inspection is defined as: An intensive examination of a specific item, 

installation, or assembly to detect damage, failure, or irregularity. Available lighting is 

normally supplemented with a direct source of good lighting at an intensity deemed 

appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be necessary. 

Surface cleaning and elaborate procedures may be required.

7. These work instructions refer to procedures included on other Boeing documents. 

When the words "refer to" are used and the operator has an accepted alternative 

procedure, the accepted alternative procedure can be used. When the words "in 

accordance with" are included in the instruction, the procedure in the Boeing document 

must be used.
 

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

2. Do an inspection of the left windshield as given in Figure 1. 

3. If the left windshield is not in a serviceable condition, replace it before the subsequent revenue 

flight. Refer to 757 AMM 56-11-01 as an accepted procedure.

4. Remove the DO-NOT-CLOSE tag and close the applicable circuit breaker shown below:

WORK PACKAGE 2 - INSPECTION OF THE RIGHT WINDSHIELD

WARNING: BEFORE YOU DO MAINTENANCE ON THE WINDSHIELD HEAT SYSTEM, OPEN

THE CIRCUIT BREAKER GIVEN IN THE STEP THAT FOLLOWS. IF THIS CIRCUIT

BREAKER IS NOT OPEN, YOU CAN GET AN ELECTRICAL SHOCK WHEN YOU

TOUCH THE TERMINAL.

1. Open this circuit breaker and attach a DO-NOT-CLOSE tag to it:

2. Do an inspection of the right windshield as given in Figure 2. 

3. If the right windshield is not in a serviceable condition, replace it before the subsequent revenue 

flight. Refer to 757 AMM 56-11-01 as an accepted procedure. 

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

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

Panel Position Name Circuit Breaker

P70 C13 WINDOW HTR 1L C391

Panel Position Name Circuit Breaker

P70 C13 WINDOW HTR 1L C391

Panel Position Name Circuit Breaker

P37 J2 WINDOW HTR 1R C392

Panel Position Name Circuit Breaker

P37 J2 WINDOW HTR 1R C392
 

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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:

2. Remove the left windshield. Use the windshield handling sling, A56001-2. Refer to 757 AMM 

56-11-01 as an accepted procedure. 

3. Cut the bulb seal for the left windshield as given in Figure 3.

4. Change the wiring for the window heat on the left windshield as given in Figure 4 and Figure 5.

5. 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:

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

8. Do the test "Operational Test - Flight Compartment Window Anti-Icing System" as given in 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:

Panel Position Name Circuit Breaker

P70 C13 WINDOW HTR 1L C391

Description Part Number Part of Top Kit

Left Windshield with 

Hydrophobic Coating

141W7400-43 012N8926-13

Panel Position Name Circuit Breaker

P70 C13 WINDOW HTR 1L C391

Panel Position Name Circuit Breaker

P37 J2 WINDOW HTR 1R C392
 

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2. Remove the right windshield. Use the windshield handling sling, A56001-2. Refer to 757 AMM 

56-11-01 as an accepted procedure.

3. Cut the bulb seal for the right windshield as given in Figure 6.

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

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

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.

Description Part Number Part of Top Kit

Right Windshield with 

Hydrophobic Coating

141W7400-44 012N8926-14

Panel Position Name Circuit Breaker

P37 J2 WINDOW HTR 1R C392
 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

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FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

FWD

INBD

TERMINAL

BLOCK,

CONNECTOR

1

3 SCREW

J5

2 LUG

J4 J1

TB5028

W2304

2

LUG

3 SCREW

4

5

1 TERMINAL

BLOCK,

CONNECTOR

4

5

2

LUG

3 SCREW

4

5

1 TERMINAL

BLOCK,

CONNECTOR

485157

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

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LUG PARALLEL

TO TERMINAL LUG

(WB0710

SHOWN)

TERMINAL

LUG NOT PARALLEL

TO TERMINAL

LUG

(WB0710

SHOWN)

TERMINAL

WALLACE AND BLACK LUG

TERMINAL TERMINAL

LUG

(CWC01-1210

SHOWN)

LUG

(CWC01-1210

SHOWN)

LUG NOT PARALLEL

TO TERMINAL AND

O-RING NOT EVENLY

COMPRESSED

LUG PARALLEL TO

TERMINAL AND

O-RING EVENLY

COMPRESSED

ACCEPTABLE 

LUG PARALLEL TO TERMINAL

NOT ACCEPTABLE 

LUG NOT PARALLEL TO TERMINAL

CORY / TRI-STAR LUG

ACCEPTABLE 

LUG PARALLEL TO TERMINAL

NOT ACCEPTABLE 

LUG NOT PARALLEL TO TERMINAL

1650858

(SHEET 2 OF 5)
 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

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TERMINAL

LUG

SCREW

LOCKWASHER

COVER

SCREW

LOCKWASHER

COVER

O-RING

WALLACE AND BLACK LUG

LUG

TERMINAL

1

1

3 4 5

5

4 5

3 4 5

5

4 5

5

CORY / TRI-STAR LUG

4 2 4 6 7

4

1 2 4 6

1 4

1 3

1673473

(SHEET 3 OF 5)
 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. 

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1

Inspect Terminal Block J1, J4, J5 3 At the J1, J4 and J5 connection

Connector - 3

Wiring Wire bundle W2304 3

NOTE: If the terminal lug or cap has melted, replace the shipside terminal lug and windshield.

NOTE: If the terminal block has melted, distorted or cracked, replace the windshield.

NOTE: If the shipside wire insulation has melted or discolored, then repair or replace shipside

wiring as necessary. Refer to Standard Wiring Practices Manual SWPM 20-10-13 as

an accepted procedure.

2

Inspect Lug - 3 to make sure it is a 

tight connection.

NOTE: If the terminal lug moves while applying light manual pressure to the strain-relief on

lug, then the screw that attaches it must be tightened. There are four causes for a

loose terminal.

1-The screw is not tightened to the correct torque.

2-The terminal is damaged.

3-The incorrect screw is installed. The correct screw part number is given in SWPM

20-64-16 and Illustrated Parts Catalog 757 IPC 30-41-52.

4-The screw is cross threaded.

NOTE: If the lug is not parallel with the terminal, then the screw is cross threaded. Check for

lug alignment, the lug and terminal must be viewed from the side. It may be

necessary to view the lug and terminal from the exterior side of the window.

NOTE: If the lug shows signs of arcing, blueing, overheating or melting, replace the lug and

windshield.

CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH

FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE

WINDOW

3

Torque Screw - 3 to 25 to 30 inch pounds of torque. 

Refer to SWPM 20-64-16 as an 

accepted procedure. 

Inspect Lug 3 to make sure the connection is 

tight. 

NOTE: The screw is only tightened if the lug is loose. If it is the correct screw and it cannot

be tightened to 25 to 30 inch pounds, do steps 4 and 5.

NOTE: If the cross threaded screw can not be tightened, replace the window.

(SHEET 4 OF 5)
 FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD

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4

Remove/

Keep

Cover - 3

Remove Screw - 3 To make sure the correct screw is 

installed and there is no damage to 

terminal, lug or screw.

Washer - 3

Inspect Terminal J1, J4, J5 3 To make sure the terminal or lug is 

not damaged. Lug - 3

NOTE: If the terminal block mating surface has contamination, clean surface. Refer to SWPM

20-20-00 Cleaning Method 5 as an accepted procedure. If the terminal shows signs

of arcing, blueing or overheating, the window must be replaced.

NOTE: If the mating surface on the terminal lug has contamination, clean surface. Refer to

SWPM 20-20-00 Cleaning Method 5 as an accepted procedure. If the lug cannot be

cleaned or shows signs of arcing, blueing or overheating, the lug must be replaced.

CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH

FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE

WINDOW

5

Install 

(New)

Screw - 3 To make sure lug is assembled to 

terminal with new, undamaged and 

correct hardware.

Washer - 3

O-ring - 3

NOTE: Reassemble the lug to the terminal with a new screw, lock washer and o-ring. Make

sure the o-ring is installed prior to assemble of the lug to the terminal. A new o-ring is

only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 or 757 IPC

30-41-52 for the correct screw, washer and o-ring.

NOTE: Make sure the screw has been aligned correctly.

Torque Screw - 3 To 25 to 30 inch pounds of torque. 

Refer to SWPM 20-64-16 as an 

accepted procedure.

NOTE: Do step 2 to make sure the screw has been installed correctly and is a tight

connection.

 6 Inspect Lug - 3 Apply light manual pressure to 

strain-relief on lug.

NOTE: If the lug moves with light manual pressure, replace the windshield.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

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

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BOEING SERVICE BULLETIN 757-30-0020

FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

FWD

INBD

TERMINAL

BLOCK,

CONNECTOR

1

2 LUG

J5

3 SCREW

J1 J4

W2314

TB5038

4

5

3 SCREW

4

5

1

TERMINAL

BLOCK,

CONNECTOR

2

LUG

3 SCREW

4

5

2

LUG 1

TERMINAL

BLOCK,

CONNECTOR

485158

(SHEET 1 OF 5)
 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

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BOEING SERVICE BULLETIN 757-30-0020

LUG PARALLEL

TO TERMINAL LUG

(WB0710

SHOWN)

TERMINAL

LUG NOT PARALLEL

TO TERMINAL

LUG

(WB0710

SHOWN)

TERMINAL

WALLACE AND BLACK LUG

TERMINAL TERMINAL

LUG

(CWC01-1210

SHOWN)

LUG

(CWC01-1210

SHOWN)

LUG NOT PARALLEL

TO TERMINAL AND

O-RING NOT EVENLY

COMPRESSED

LUG PARALLEL TO

TERMINAL AND

O-RING EVENLY

COMPRESSED

ACCEPTABLE 

LUG PARALLEL TO TERMINAL

NOT ACCEPTABLE 

LUG NOT PARALLEL TO TERMINAL

CORY / TRI-STAR LUG

ACCEPTABLE 

LUG PARALLEL TO TERMINAL

NOT ACCEPTABLE 

LUG NOT PARALLEL TO TERMINAL

1650857

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

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BOEING SERVICE BULLETIN 757-30-0020

TERMINAL

LUG

SCREW

LOCKWASHER

COVER

SCREW

LOCKWASHER

COVER

O-RING

WALLACE AND BLACK LUG

LUG

TERMINAL

1

1

3 4 5

5

4 5

3 4 5

5

4 5

5

CORY / TRI-STAR LUG

4 2 4 6 7

4

1 2 4 6

1 4

1 3

1676457

(SHEET 3 OF 5)
 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

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BOEING SERVICE BULLETIN 757-30-0020

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. 

STEP TASK NAME IDENTIFICATION QTY MORE DATA

1

Inspect Terminal Block J1, J4, J5 3 At the J1, J4 and J5 connection

Connector - 3

Wiring Wire bundle W2304 3

NOTE: If the terminal lug or cap has melted, replace the shipside terminal lug and windshield.

NOTE: If the terminal block has melted, distorted or cracked, replace the windshield.

NOTE: If the shipside wire insulation has melted or discolored, then repair or replace shipside

wiring as necessary. Refer to Standard Wiring Practices Manual SWPM 20-10-13 as

an accepted procedure.

2

Inspect Lug - 3 to make sure it is a 

tight connection.

NOTE: If the terminal lug moves while applying light manual pressure to the strain-relief on

lug, then the screw that attaches it must be tightened. There are four causes for a

loose terminal.

1-The screw is not tightened to the correct torque.

2-The terminal is damaged.

3-The incorrect screw is installed. The correct screw part number is given in SWPM

20-64-16 and Illustrated Parts Catalog 757 IPC 30-41-52.

4-The screw is cross threaded.

NOTE: If the lug is not parallel with the terminal, then the screw is cross threaded. Check for

lug alignment, the lug and terminal must be viewed from the side. It may be

necessary to view the lug and terminal from the exterior side of the window.

NOTE: If the lug shows signs of arcing, blueing, overheating or melting, replace the lug and

windshield.

CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH

FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE

WINDOW

3

Torque Screw - 3 to 25 to 30 inch pounds of torque. 

Refer to SWPM 20-64-16 as an 

accepted procedure. 

Inspect Lug 3 to make sure the connection is 

tight. 

NOTE: The screw is only tightened if the lug is loose. If it is the correct screw and it cannot

be tightened to 25 to 30 inch pounds, do steps 4 and 5.

NOTE: If the cross threaded screw can not be tightened, replace the window.

(SHEET 4 OF 5)
 FIGURE 2: INSPECTION OF THE RIGHT WINDSHIELD

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Revision 2: March 31, 2010 757-30-0020

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BOEING SERVICE BULLETIN 757-30-0020

4

Remove/

Keep

Cover - 3

Remove Screw - 3 To make sure the correct screw is 

installed and there is no damage to 

terminal, lug or screw.

Washer - 3

Inspect Terminal J1, J4, J5 3 To make sure the terminal or lug is 

not damaged. Lug - 3

NOTE: If the terminal block mating surface has contamination, clean surface. Refer to SWPM

20-20-00 Cleaning Method 5 as an accepted procedure. If the terminal shows signs

of arcing, blueing or overheating, the window must be replaced.

NOTE: If the mating surface on the terminal lug has contamination, clean surface. Refer to

SWPM 20-20-00 Cleaning Method 5 as an accepted procedure. If the lug cannot be

cleaned or shows signs of arcing, blueing or overheating, the lug must be replaced.

CAUTION: DO NOT OVER TIGHTEN. THE TERMINAL CAN BE DAMAGED BY TOO MUCH

FORCE. A DAMAGED TERMINAL WILL REQUIRE THE REPLACEMENT OF THE

WINDOW

5

Install 

(New)

Screw - 3 To make sure lug is assembled to 

terminal with new, undamaged and 

correct hardware.

Washer - 3

O-ring - 3

NOTE: Reassemble the lug to the terminal with a new screw, lock washer and o-ring. Make

sure the o-ring is installed prior to assemble of the lug to the terminal. A new o-ring is

only available for the CWC01-1210 lug. Refer to SWPM 20-64-16 or 757 IPC

30-41-52 for the correct screw, washer and o-ring.

NOTE: Make sure the screw has been aligned correctly.

Torque Screw - 3 To 25 to 30 inch pounds of torque. 

Refer to SWPM 20-64-16 as an 

accepted procedure.

NOTE: Do step 2 to make sure the screw has been installed correctly and is a tight

connection.

 6 Inspect Lug - 3 Apply light manual pressure to 

strain-relief on lug.

NOTE: If the lug moves with light manual pressure, replace the windshield.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

(SHEET 5 OF 5)
 FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD

July 19, 2006

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BOEING SERVICE BULLETIN 757-30-0020

FIGURE 3: CUT THE BULB SEAL FOR THE LEFT WINDSHIELD 

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

CAUTION: DO NOT CUT THE STRUCTURE BELOW THE BULB SEAL. THE WINDOW

SILL IS A HIGH MOISTURE AREA AND MOISTURE CAN CAUSE CORROSION

IF THE FINISH IS DAMAGED. DAMAGE TO THE FINISH MUST BE REPAIRED. 

1

Cut Bulb Seal 233T8300-7 - to clear the new 

terminal.

NOTE: If the finish below the bulb seal is damaged, it 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.

GLARESHIELD

BULB SEAL

1 1.20

1.40

485159

(SHEET 1 OF 1)
 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD

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Revision 2: March 31, 2010 757-30-0020

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BOEING SERVICE BULLETIN 757-30-0020

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

=1

D3322

=1

=1

D3326

D3324

A-AC

B35 LEFT WINDOW 1

=1

J5

0002-12

B35 LEFT WINDOW 1

=1

J1

TB5028

STA 225

WL 225

LBL 37

0001-12

W2304

1

2

A-AA

A-AB

4

4

5

5

3

3

2

1

ADDED WIRE OR NEW ROUTING

DELETED WIRE OR FORMER ROUTING

REFERENCE: WIRING DIAGRAM 30-41-11

485160

(SHEET 1 OF 2)
 FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD

Original Issue: July 19, 2006

Revision 2: March 31, 2010 757-30-0020

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BOEING SERVICE BULLETIN 757-30-0020

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG 

NOTE NAME IDENTIFICATION QTY MORE DATA

1 Wire BMS 13-60, Type 1, 

Class 1, AWG 12

1

2 Wire BMS 13-60, Type 1, 

Class 1, AWG 12

1

Lacing Tape BMS 13-54, Type 3, 

Class 1, Red

 - or optional BACS38K5C Tie Strap.

Red is for left channel separation. 

Refer to Standard Wiring Practices 

Manual SWPM 20-10-19 as an 

accepted procedure.

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

accepted procedure.

4 Socket Contact M39029/57-359 2 Refer to SWPM 20-63-19 as an 

accepted procedure.

NOTE: Isopropyl alcohol is applied to the installation tool and on the contact before

installation of the contact. Isopropyl alcohol is a lubricant that helps with

installation of the contact in the connector.

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

accepted procedure.

(SHEET 2 OF 2)
 FIGURE 5: WIRE ROUTING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD

July 19, 2006

Revision 2: March 31, 2010 757-30-0020

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BOEING SERVICE BULLETIN 757-30-0020

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

FWD

INBD

W2304

W2304

J1

TB5028

J5

485162

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

Original Issue: July 19, 2006

Revision 2: March 31, 2010 757-30-0020

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BOEING SERVICE BULLETIN 757-30-0020

FIGURE 6: CUT THE BULB SEAL FOR THE RIGHT WINDSHIELD

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. 

STEP TASK NAME IDENTIFICATION QTY MORE DATA

CAUTION: DO NOT CUT THE STRUCTURE BELOW THE BULB SEAL. THE WINDOW

SILL IS A HIGH MOISTURE AREA AND MOISTURE CAN CAUSE CORROSION

IF THE FINISH IS DAMAGED. DAMAGE TO THE FINISH MUST BE REPAIRED. 

1

Cut Bulb Seal 233T8300-8 - to clear the new 

terminal.

NOTE: If the finish below the bulb seal is damaged, it must be sealed with chemical

treatment and primer. Refer to Standard Overhaul Practices Manual SOPM

20-41-02 and 20-43-03, if necessary.

2 Identify Glareshield - (a)

(a) Part mark with service bulletin number before new windshield is installed. Refer to SOPM 

20-50-10 as an accepted procedure.

1.40 1

BULB SEAL

1.20

2

485163

(SHEET 1 OF 1)
 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD

Original Issue: July 19, 2006

Revision 2: March 31, 2010 757-30-0020

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BOEING SERVICE BULLETIN 757-30-0020

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

A-AB

A-AA

2

1

0001-12

J1

=1

0002-12

J5

=1

A-AC =1

=1

=1

W2314

D3270

D3272

D3274

TB5038

STA 223

WL 230

RBL 40

B38 RIGHT WINDOW 1

B38 RIGHT WINDOW 1

1

2

3

3

5

5

4

4

ADDED WIRE OR NEW ROUTING

DELETED WIRE OR FORMER ROUTING

REFERENCE: WIRING DIAGRAM 30-41-12

485169

(SHEET 1 OF 2)
 FIGURE 7: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD

Original Issue: July 19, 2006

Revision 2: March 31, 2010 757-30-0020

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 48

BOEING SERVICE BULLETIN 757-30-0020

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG 

NOTE NAME IDENTIFICATION QTY MORE DATA

1 Wire BMS 13-60, Type 1, 

Class 1, AWG 12

1

2 Wire BMS 13-60, Type 1, 

Class 1, AWG 12

1

Lacing Tape BMS 13-54, Type 3, 

Class 1, Green

or optional BACS38K5F Tie Strap.

Green is for right channel separation. 

Refer to Standard Wiring Practices 

Manual SWPM 20-10-19 as an 

accepted procedure.

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

accepted procedure.

4 Socket Contact M39029/57-359 2 Refer to SWPM 20-63-19 as an 

accepted procedure.

NOTE: Isopropyl alcohol is applied to the installation tool and on the contact before

installation of the contact. Isopropyl alcohol is a lubricant that helps with

installation of the contact in the connector.

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

accepted procedure.

(SHEET 2 OF 2)
 FIGURE 8: WIRE ROUTING FOR THE WINDOW HEAT ON THE RIGHT WINDSHIELD

July 19, 2006

Revision 2: March 31, 2010 757-30-0020

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BOEING SERVICE BULLETIN 757-30-0020

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

J1

J5

FWD

INBD

TB5038

W2314

W2314

485170

(SHEET 1 OF 1)