July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 48 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## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2006 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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 or otherwise.**BLANK PAGE** July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

BLANK PAGE**Table of Contents** July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 48 

### BOEING SERVICE BU **LLETIN 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**Table of Contents** July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

BLANK PAGEOriginal Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 48 

### 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.Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

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 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 48 

### 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.Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 48 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 4.75Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 48 

### BOEING SERVICE BU **LLETIN 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:Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

BLANK PAGEOriginal Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 48 

### 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.Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 48 

### 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 1Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 48 

### BOEING SERVICE BU **LLETIN 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.Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 48 

### 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.Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 48 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)**Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 48 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)**Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 48 

### BOEING SERVICE BU **LLETIN 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)**Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

— Time to find the tools.

**H. Weight and Balance Changes**
None Work Package 1 - Inspection of the Left Windshield
**Task Number of**  **Persons Task-Hours Elapsed Hours** Figure 1 1 1.50 1.50 Total per Windshield 1.50 1.50 Work Package 2 - Inspection of the RIght Windshield
**Task Number of**  **Persons Task-Hours Elapsed Hours** Figure 2 1 1.50 1.50 Total per Windshield 1.50 1.50 Work Package 3 - Replacement of the Left Windshield and Changes to the Related Wiring
**Task Number of**  **Persons Task-Hours Elapsed Hours** Access 2 1.0 0.50 Remove the Left Windshield 2 2.5 1.25 Figure 3 - Cut the Bulb Seal 1 0.25 0.25 Figures 4 and 5 - Change the Wiring 1 0.50 0.50
Install the Left Windshield 2 3.0 1.5 Tests 1 0.25 0.25 Close 2 1.0 0.50 Total per Windshield 8.5 4.75 Work Package 4 - Replacement of the Right Windshield and Changes to the Related Wiring
**Task Number of**  **Persons Task-Hours Elapsed Hours** Access 2 1.0 0.50 Remove the Right Windshield 2 2.5 1.25 Figure 6 - Cut the Bulb Seal 1 0.25 0.25 Figures 7 and 8 - Change the Wiring 1 0.50 0.50 Install the Right Windshield 2 3.0 1.5 Tests 1 0.25 0.25 Close 2 1.0 0.50 Total per Windshield 8.5 4.75Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

**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 56-11Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

**L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information.July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

**2. MATERIAL INFORMATION A. Material - Price and Availability**  Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane 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 $16,480.00July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

**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 35811-9660July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

**Kit 280N3355 New Part**  **Number QTY**  **Name Notes -102 -101 -2 -1**  280N3355-1 . . . - Wire Kit - Flight Deck Window Heat 280N3355-2 . . - . Wire Kit - Flight Deck Window Heat 280N3355-101 . - . 1 Kit, Wire Bundle W2304 280N3355-102 - . 1 . Kit, Wire Bundle W2314 280N3355-10103 . 1 . . BMS 13-52 Expandable Sleeve 280N3355-10203 1 . . . BMS 13-52 Expandable Sleeve - . 1 . . Wire Identified W2304-0001-12 (a) - . 1 . . Wire Identified W2304-0002-12 (b) - 1 . . . Wire Identified W2314-0001-12 (a) - 1 . . . Wire Identified W2314-0002-12 (b) BACT12AC-12 3 3 . . Terminal Lug (c) M39029/57-359 3 3 . . Socket Contact (c) (a) BMS 13-60, Type 1, Class 1, AWG 12, length 66 inches (b) BMS 13-60, Type 1, Class 1, AWG 12, length 33 inches (c) There are more parts than are necessary.July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified: The parts shown below are changed as shown in this service bulletin. The quantity (QTY) is the number of parts changed on each airplane.

4. Parts Removed and Not Replaced: None **D. Parts Necessary to Change Spares**
None **Part Number / Specification QTY Name Notes**  BMS 13-54 10 feet Lacing Tape, Red (a) (b) (c) BMS 13-54 10 feet Lacing Tape, Green (a) (b) (d) (a) Type 3, Class 1 (b) Gudebrod Incorporated (V82110) Griffith Towers PO Box 357 Pottstown, PA 19464 (c) BACS38K5C, red Tie Strap is optional. See the Qualified Products List at the end of the Boeing Material Specification (BMS) for the supplier data. (d) BACS38K5F, green Tie Strap is optional. See the Qualified Products List at the end of the Boeing Material Specification (BMS) for the supplier data.

**Existing Part Number QTY Name New Part Number Notes**  233N8300-( ) 1 Glareshield - (a) (b) (a) Make the change given in this service bulletin. (b) There is no equivalent Boeing part number for the changed part. Identify on the part that the change given in this service bulletin was made.July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

**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 SlingJuly 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

BLANK PAGEOriginal Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

**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.Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

**B. WORK INSTRUCTIONS WORK PACKAGE 1 - INSPECTION OF THE LEFT WINDSHIELD**  **WARNING:** BEFORE YOU DO MAINTENANCE ON THE WINDSHIELD HEAT SYSTEM, OPEN THE CIRCUIT BREAKER GIVEN IN THE STEP THAT FOLLOWS. IF THIS CIRCUIT BREAKER IS NOT OPEN, YOU CAN GET AN ELECTRICAL SHOCK WHEN YOU TOUCH THE TERMINAL. 1. Open the applicable circuit breaker shown below and attach a DO-NOT-CLOSE tag to it:

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 C392Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

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 C392Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

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** Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

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

FWD INBD TERMINAL BLOCK, CONNECTOR 1 SCREW 3 J5

2 LUG J4 J1

TB5028 W 2 3 0 4 2 LUG SCREW 3 4 5

1 TERMINAL BLOCK, CONNECTOR

4 5 2 LUG SCREW 3 4 5

1 TERMINAL BLOCK, CONNECTOR485157

**(SHEET 1 OF 5) FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 48 

### 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 TERMINAL1650858

**(SHEET 2 OF 5) FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 48 

### BOEING SERVICE BU **LLETIN 757-30-0020**

TERMINAL LUG SCREW

LOCKWASHER COVER

SCREW

LOCKWASHER

COVER

O-RING 

### WALLACE AND BLACK LUG

LUG

TERMINAL 1 1 5 4 3

5 5 4

5 4 3

5 5 4

5



### CORY / TRI-STAR LUG

4 2 4 6 7

4

1 2 4 6

1 4 1 31673473

**(SHEET 3 OF 5) FIGURE 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 48 

### 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 1: INSPECTION OF THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 48 

### BOEING SERVICE BU **LLETIN 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 2: INSPECTION OF 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. 36 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

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

FWD INBD TERMINAL BLOCK, CONNECTOR 1

LUG 2 J5 3 SCREW J1 J4 W 2 3 1 4

TB5038 4 5 SCREW 3 4 5

1 TERMINAL BLOCK, CONNECTOR 2 LUG SCREW 3 4 5

2 LUG 1 TERMINAL BLOCK, CONNECTOR485158

**(SHEET 1 OF 5) FIGURE 2: INSPECTION OF 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. 37 of 48 

### BOEING SERVICE BU **LLETIN 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 TERMINAL1650857

**(SHEET 2 OF 5) FIGURE 2: INSPECTION OF 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. 38 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

TERMINAL LUG SCREW

LOCKWASHER COVER

SCREW

LOCKWASHER

COVER

O-RING 

### WALLACE AND BLACK LUG

LUG

TERMINAL 1 1 5 4 3

5 5 4

5 4 3

5 5 4

5



### CORY / TRI-STAR LUG

4 2 4 6 7

4

1 2 4 6

1 4 1 31676457

**(SHEET 3 OF 5) FIGURE 2: INSPECTION OF 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. 39 of 48 

### BOEING SERVICE BU **LLETIN 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**  Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 48 

### 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 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 48 

### BOEING SERVICE BU **LLETIN 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 1.40485159

**(SHEET 1 OF 1) FIGURE 4: CHANGES TO THE WIRING FOR THE WINDOW HEAT ON THE LEFT WINDSHIELD**  Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 48 

### 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 30-41-11485160

**(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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 48 

### BOEING SERVICE BU **LLETIN 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

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

FWD INBD W2304 W2304 J1

TB5028 J5485162

**(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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 48 

### BOEING SERVICE BU **LLETIN 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 2485163

**(SHEET 1 OF 1) FIGURE 7: CHANGES TO THE WIRING FO**  **R THE WINDOW HEAT ON THE RIGHT WINDSHIELD** Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

**FIGURE 7: CHANGES TO THE WIRING FOR TH E 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 30-41-12485169

**(SHEET 1 OF 2) FIGURE 7: CHANGES TO THE WIRING FO**  **R THE WINDOW HEAT ON THE RIGHT WINDSHIELD** Original Issue: July 19, 2006 Revision 2: March 31, 2010 757-30-0020 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 48 

### BOEING SERVICE BU **LLETIN 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 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 48 of 48 

### BOEING SERVICE BULLETIN 757-30-0020

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

J1

J5

FWD INBD TB5038 W2314 W2314485170

**(SHEET 1 OF 1)**