April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 47 

### Commercial **Airplane Group**  

# 777

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 777-30-0012** Date: April 07, 2004 Revision 2: December 19, 2007 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Ice - Number 1 Left and Right Window Replacement and Wire Changes 

## BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2004 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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or otherwise.**BLANK PAGE** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 2 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

BLANK PAGE**Table of Contents** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 3 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**Table of Contents** Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 20 3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 21 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 21 2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 26 3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 27 3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 FIGURE 1: CUT THE BULB SEAL FOR THE LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW 34 FIGURE 2: WIRING CHANGE FOR THE LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW . . 36 FIGURE 3: CUT THE BULB SEAL FOR THE RI GHT NUMBER 1 FLIGHT COMPARTMENT WINDOW39 FIGURE 4: WIRING CHANGE FOR THE RIGHT NUM BER 1 FLIGHT COMPARTMENT WINDOW. . 41 FIGURE 5: INSPECTION OF AN ELECTRICAL CONNECTION ON THE LEFT NUMBER 1 WINDOW 44 FIGURE 6: INSPECTION OF AN ELECTRICAL CONNECTION ON THE RIGHT NUMBER 1 WINDOW . 46**Table of Contents** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 4 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

BLANK PAGEApril 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 5 of 47 

### Commercial **Airplane Group**  

# 777

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 777-30-0012** 

### Revision Transmittal Sheet Date: April 07, 2004 Revision 2: December 19, 2007 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Ice - Number 1 Left and Right Window Replacement and Wire Changes
This Revision includes all pages of the service bulletin. **COMPLIANCE INFORMATION RELATED TO THIS REVISION** No more work is necessary on airplanes changed as shown in the original issue or Revision 1 of this service bulletin. This revision is sent to change the No.1 Windshield Assembly part numbers supplied in the Top Kits. **REASON FOR REVISION** These sections were changed: 1. In Planning Information 1.J., Standard Overhaul Practices Manual (SOPM) reference 20-50-10 and Boeing Service Bulletin reference 777-56-0002 have been added to existing data. 2. In Material Information 2.A., Material Price and Availability, the Price and Rolt information has been updated. 3. In Material Information 2.C., Parts Necessary For Each Airplane, the No.1 Windshield Assembly part numbers been have changed. 4. In Material Information 2.E., Special Tooling - Pricing and Availability, the Tool Kit price has been updated. 5. In Accomplishment Instructions 3.B., Work Instructions, Work Package 1, the circuit breaker tables have been changes to open and close the circuit breakers for the left number 1 window. 6. In Accomplishment Instructions 3.B., Work Instructions, Work Package 2, the circuit breaker tables have been changes to open and close the circuit breakers for the right number 1 window. 7. In Accomplishment Instructions 3.B., Work Instructions, step 5 of Work Package 3 and Work Package 4, the No.1 Windshield Assembly part numbers have changed. 8. In Figure 1, a new step has been added to the step table to part mark the glareshield. 9. In Figure 3, a new step has been added to the step table to part mark the glareshield.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 6 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

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: April 07, 2004 Revision 1: June 02, 2006 Revision 2: December 19, 2007April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 7 of 47 

### Commercial **Airplane Group**  

# 777

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 777-30-0012** 

### Summary Date: April 07, 2004 Revision 2: December 19, 2007 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Ice - Number 1 Left and Right Window Replacement and Wire Changes

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **CONCURRENT REQUIREMENTS**
None **BACKGROUND** This service bulletin gives instructions to do an inspection in the flight compartment of an electrical connection on the left and the right number 1 windows. Instructions are also given to replace the windows and make changes to their related wire bundles. A new design window 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 it 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. All of the windows in the flight compartment are electrically heated. The number 1 windows get 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.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 8 of 47 When the changes given in this bulletin are done, the number 1 windows 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 Problem (SRP) 777-SRP-56-0015 is related to this service bulletin. **ACTION** (PRR 62777-28S) In the flight compartment, do an inspection of the J5 terminal on the left and the right number 1 windows. Replace number 1 windows that use screws and lugs for the electrical connections with a window 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** Refer to service bulletin Paragraph 1.A.1 for effectivity. **COMPLIANCE** 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 0.25 0.25 Work Package 2 0.25 0.25 Work Package 3 8.5 4.75 Work Package 4 8.5 4.75April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

WORK PACKAGE 4: CUT THE BULB SEAL. REPLACE THE RIGHT NUMBER 1 WINDOW. CHANGE THE RELATED WIRING.

NUMBER 1 WINDOW. INSPECT THE RIGHT WORK PACKAGE 2:

INSPECT THE LEFT NUMBER 1 WINDOW. WORK PACKAGE 1: WORK PACKAGE 3: CUT THE BULB SEAL. REPLACE THE LEFT NUMBER 1 WINDOW. CHANGE THE RELATED WIRING.363654April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 10 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

BLANK PAGEApril 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 11 of 47 

### Commercial **Airplane Group**  

# 777

**SPECIAL ATTENTION** 

# Service Bulletin

**Number: 777-30-0012** Date: April 07, 2004 Revision 2: December 19, 2007 ATA System: 3041 5611 **SUBJECT:** ICE AND RAIN PROTECTION - Flight Compartment Window Anti-Ice - Number 1 Left and Right Window Replacement and Wire Changes

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes Refer to Service Bulletin Index Document D624W001 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 62777-28 for data about this change.

Airplane models:
777-200 777-300 IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER AEROMEXICO (AMX) 1 WB341 AIR AUSTRAL (AUX) 1 WB366–WB367 AIR CHINA (BEJ) 1 WA241–WA250 AIR FRANCE (AFA) 1 WB311–WB335 **GROUP CONFIGURATION DESCRIPTION** 1 - Airplanes that have number 1 windows with lugs and screws for the electrical connections.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 12 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

AIR INDIA (AIN) 1 WA007 WB058–WB059 WB070 AIRCRAFT MARKETING LTD. (CFK) 1 WA079–WA080 ALITALIA (ALI) 1 WC281–WC289 ALL NIPPON AIRWAYS (ANA) 1 WA131–WA137 WA221–WA223 WA231–WA232 WB481–WB484 WB531–WB537 AMERICAN AIRLINES (AAL) 1 WB416–WB437 WC051–WC073 ASIANA AIRLINES (AAR) 1 WC111–WC114 AUSTRIAN (AUL) 1 WB271–WB273 BRITISH AIRWAYS (BAB) 1 WA076–WA078 WB001–WB021 WB031–WB046 WB411–WB413 CATHAY PACIFIC AIRWAYS (CAT) 1 WA001 WA101–WA104 WB501–WB510 CHINA SOUTHERN AIRLINES (GUN) 1 WA116–WA119 WB121–WB125 CONTINENTAL AIRLINES (CAL) 1 WB371–WB388 DELTA AIR LINES (DAL) 1 WB446–WB453 EGYPTAIR (EGP) 1 WB151–WB155 EL AL ISRAEL AIRLINES (ELA) 1 WC101–WC104 EMIRATES (EAD) 1 WA196–WA198 WB101–WB106 WB631–WB638 WB646–WB649 ILFC (ILF) 1 WB342 JAL INTERNATIONAL (JAL) 1 WA171–WA175 WA206–WA212 WA281 WB591–WB597 WC241–WC243 WC301–WC303April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 13 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

KLM - ROYAL DUTCH AIRLINES (KLM) 1 WC381–WC385 KOREAN AIR (KAL) 1 WB131–WB139 WB551–WB554 KUWAIT AIRWAYS (KUW) 1 WB306–WB307 MALAYSIA AIRLINES (MAS) 1 WB161–WB175 MID EAST JET (SKL) 1 WB406 PAKISTAN INT'L AIRLINES (PIA) 1 WC446–WC447 ROYAL BRUNEI AIRLINES (RBA) 1 WB072–WB073 SAUDI ARABIAN AIRLINES (SVA) 1 WB276–WB286 WB291–WB302 SAUDI OGER (SAO) 1 WB476 SINGAPORE AIRLINES (SIA) 1 WB181–WB192 WB201–WB214 WB231–WB247 WB611–WB618 THAI AIRWAYS INTERNATIONAL (TII) 1 WA086–WA093 WB601–WB606 UNITED AIRLINES (UAL) 1 WA002–WA006 WA009–WA010 WA012–WA017 WA261–WA266 WB051–WB057 WB060–WB069 WB071 WB074–WB088 VARIG AIRLINES (VAR) 1 WA008 WA011 VIETNAM AIRLINES (VIE) 1 WB336–WB337 WC361–WC362 WC371–WC372 IDENTIFICATION BY VARIABLE NUMBER **Variable Group** WA001–WA017 1 WA076–WA080 1 WA086–WA093 1 WA101–WA104 1 WA116–WA119 1April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 14 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

WA131–WA137 1 WA171–WA175 1 WA196–WA198 1 WA206–WA212 1 WA221–WA223 1 WA231–WA232 1 WA241–WA250 1 WA261–WA266 1 WA281 1 WB001–WB021 1 WB031–WB046 1 WB051–WB088 1 WB101–WB106 1 WB121–WB125 1 WB131–WB139 1 WB151–WB155 1 WB161–WB175 1 WB181–WB192 1 WB201–WB214 1 WB231–WB247 1 WB271–WB273 1 WB276–WB286 1 WB291–WB302 1 WB306–WB307 1 WB311–WB337 1 WB341–WB342 1 WB366–WB367 1 WB371–WB388 1 WB406 1 WB411–WB413 1 WB416–WB437 1 WB446–WB453 1 WB476 1 WB481–WB484 1 WB501–WB510 1 WB531–WB537 1 WB551–WB554 1 WB591–WB597 1 WB601–WB606 1 **Variable Group**April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 15 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

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 in the flight compartment of an electrical connection on the left and the right number 1 windows. Instructions are also given to replace the windows and make changes to their related wire bundles. A new design window 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 it 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. All of the windows in the flight compartment are electrically heated. The number 1 windows get 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. WB611–WB618 1 WB631–WB638 1 WB646–WB649 1 WC051–WC073 1 WC101–WC104 1 WC111–WC114 1 WC241–WC243 1 WC281–WC289 1 WC301–WC303 1 WC361–WC362 1 WC371–WC372 1 WC381–WC385 1 WC446–WC447 1 **Variable Group**April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 16 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

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 number 1 windows 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 Problem (SRP) 777-SRP-56-0015 is related to this service bulletin. Revision 1 is sent to add an inspection and new top kits. The new inspection is in the flight compartment on an electrical connection of the left and the right number 1 windows. The number 1 window can be used if it passes the inspection. A window that does not pass the inspection can be replaced with the same type window. There is a time limit on how long the old number 1 windows can be used. The top kit in the initial release of this bulletin only had the kits for the wiring changes. When the wiring changes are done, it is necessary to install a window that includes the correct electrical connections. New top kits are offered for the left and the right side. Each kit includes a wire kit and a number 1 window. This makes it easy for operators to get only the top kit for the side that is changed. There can be a span of eight years from the replacement of one window until the replacement of the other window The Background and Reason sections have been changed. More data is given. The Compliance sections are revised to include tables for compliance time. The inspection compliance time is new in this revision to the bulletin. A tool for the removal and installation of the number 1 window is added to the applicable sections. It is shown in the Special Tooling section and in the Accomplishment Instructions Work Packages 1 and 2 are changed to Work Packages 3 and 4. New Work Packages 1 and 2 are added for the inspections. Figure 5 is added for the new Work Package 1. Figure 6 is added for the new Work Package 2. The Figures 2 and 4 did not include equipment identification in the wire routing illustration. The wire schematics were not correct. The instructions were not clear. The Figures in this revision show the necessary information more clearly. The tests in the original issue of this bulletin contained errors. There were more tests in the instructions than were necessary. The tests referred to test equipment that was not necessary. Instructions were also given to do the tests given in the maintenance manual. The tests and the special test equipment that are not necessary are removed in Revision 1.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 17 of 47 Revision 2 is sent to change the No.1 Windshield Assembly part numbers supplied in the Top Kits. These sections were changed: 1. In Planning Information 1.J., Standard Overhaul Practices Manual (SOPM) reference 20-50-10 and Boeing Service Bulletin reference 777-56-0002 have been added to existing data. 2. In Material Information 2.A., Material Price and Availability, the Price and Rolt information has been updated. 3. In Material Information 2.C., Parts Necessary For Each Airplane, the No.1 Windshield Assembly part numbers have changed. 4. In Material Information 2.E., Special Tooling - Pricing and Availability, the Tool Kit price has been updated. 5. In Accomplishment Instructions 3.B., Work Instructions, Work Package 1, the circuit breaker tables have been changes to open and close the circuit breakers for the left number 1 window. 6. In Accomplishment Instructions 3.B., Work Instructions, Work Package 2, the circuit breaker tables have been changes to open and close the circuit breakers for the right number 1 window. 7. In Accomplishment Instructions 3.B., Work Instructions, step 5 of Work Package 3 and Work Package 4, the No.1 Windshield Assembly part numbers have been changed. 8. In Figure 1, a new step has been added to the step table to part mark the glareshield. 9. In Figure 3, a new step has been added to the step table to part mark the glareshield. **D. Description** In the flight compartment, an inspection is done of the left and the right number 1 windows. 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. Revision 1 - No more work is necessary on airplanes changed as shown in the original issue of this service bulletin. Revision 2 - No more work is necessary on airplanes changed as shown in Revision 1 of this service bulletin.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 18 of 47 **E. Compliance**

**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. Compliance Sequence **Condition Action Compliance Time Repeat Interval** Number 1 windows that use screws and lugs for the electrical connections Do the Inspections given in Work Packages 1 and 2. Within 500 flight hours after the date of revision 1 to this service bulletin. Every 6000 flight hours until Work Packages 3 and 4 are done. Number 1 window replaced with the same screw and lug type window Do the Inspections given in Work Packages 1 and 2. Within 500 flight hours of the number 1 window replacement. Every 6000 flight hours until Work Packages 3 and 4 are done. Number 1 window that uses screws and lugs for the electrical connections Replace with a window that uses pins and sockets for the electrical connections as given in Work Packages 3 and 4. No time limit. Terminating action for this bulletinApril 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 19 of 47 **G. Manpower** The tables below shows an estimate of the task-hours necessary to do this change for each airplane. This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The estimate does not include lost time. These are some examples of lost time: — Time to adjust to the workplace — Time to schedule the work — Time to examine the work — Time to cure the materials — Time to make the parts — Time to find the tools. Work Package 1 - Inspection of the Left Number 1 Window
**Task Number of**  **Persons Task-Hours Elapsed Hours** Figure 5 1 0.25 0.25 Total per Window 0.25 0.25 Work Package 2 - Inspection of the Right Number 1 Window
**Task Number of**  **Persons Task-Hours Elapsed Hours** Figure 6 1 0.25 0.25 Total per Window 0.25 0.25 Work Package 3 - Replacement of the Left Number 1 Window and Changes to the Related Wiring
**Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 1.0 0.50 Remove the Left Number 1 Window 2 2.5 1.25 Figure 1 - Cut the Bulb Seal 1 0.25 0.25 Figure 2 - Change the Wiring 1 0.5 0.5
Install the Left Number 1 Window 2 3.0 1.5
Test 1 0.25 0.25 Close Access 2 1.0 0.50 Total per Window 8.5 4.75April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 20 of 47 **H. Weight and Balance Changes**
None **I. Electrical Load Data** Not changed **J. References** 1. Existing Data: a. Engineering Change Memo PRR 62777-28S b. Service Related Problem (SRP) 777-SRP-56-0015 c. 777 Aircraft Maintenance Manual (AMM) 30-41-00, 56-11-01 d. 777 Wiring Diagram 30-41-11, 30-41-12 e. Standard Wiring Practices Manual (SWPM) 20-10-11, 20-10-12, 20-10-13, 20-10-19, 20-30-12, 20-63-19 f. Standard Overhaul Practices Manual (SOPM) 20-41-02, 20-43-02, 20-43-03, 20-50-10 g. Boeing Service Bulletin 777-56-0002 2. Data supplied with this Service Bulletin:
None Work Package 4 - Replacement of the Right Number 1 Window and Changes to the Related Wiring
**Task Number of**  **Persons Task-Hours Elapsed Hours** Open Access 2 1.0 0.50 Remove the Right Number 1 Window 2 2.5 1.25 Figure 3 - Cut the Bulb Seal 1 0.25 0.25 Figure 4 - Change the Wiring 1 0.5 0.5 Install the Right Number 1 Window 2 3.0 1.5
Test 1 0.25 0.25 Close Access 2 1.0 0.50 Total per Window 8.5 4.75April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 21 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

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

These drawings were used to prepare this service bulletin. These drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. These drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected**

**L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary For Each Airplane, for interchangeability and intermixability information. **Drawing Number Title** 288W4100 Wire Bundle Instl - R.S. Cab (STA. 126.5 - 246.0) 288W4101 Wire Bundle Instl - L.S. Cab (STA. 126.5 - 246.0)

**Publication Chapter-Section** 777 Maintenance Manual 56-11 777 Wiring Diagram Manual 30-41 777 Illustrated Parts Catalog 56-11April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 22 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

BLANK PAGEApril 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 23 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**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/parts 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 31/2007** 005W3254-1 Top Kit, Flight Deck Window Heat Terminal Replacement 13 $728.00 005W3254-4 Top Kit - Left Number 1 Window with New Window Heat Terminal Connections 16 $16,600.00

005W3254-5 Top Kit - Right Number 1 Window with New Window Heat Terminal Connections 18 $16,600.00April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 24 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

**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:** 1. One left top kit and one right top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for each airplane 2. Top Kit 005W3254-1 includes the subkits to do the wiring changes for both the left and the right side of an airplane but it includes no windows. A subkit 005W3254-2 and a Window 141W7400-44 are equivalent to a top kit 005W3254-5. A subkit 005W3254-3 and a Window 141W7400-43 are equivalent to a top kit 005W3254-4.
**Kit 005W3254 New Part**  **Number QTY**  **Name Notes -5 -4 -3 -2 -1**  005W3254-1 . . . . - Top Kit - Flight Deck Window Heat Terminal Replacement (a) 005W3254-2 1 . . - 1 Sub Kit - Flight Deck Window Heat Terminal Right Side (b) 005W3254-3 . 1 - . 1 Sub Kit - Flight Deck Window Heat Terminal Left Side (c) 005W3254-4 . - . . . Top Kit - Left Number 1 Window with New Window Heat Terminal Connections 005W3254-5 - . . . . Top Kit - Right Number 1 Window with New Window Heat Terminal Connections 005W3254-101 . . 1 . . Wire Identified W4123-0111-20 (d)
005W3254-102 . . 1 . . Wire Identified W4123-0112-20 (d) 005W3254-103 . . 1 . . Wire Identified W4123-0113-12 (e) 005W3254-104 . . 1 . . Wire Identified W4123-0114-12 (e) 005W3254-106 . . . 1 . Wire Identified W4269-0111-20 (d) 005W3254-107 . . . 1 . Wire Identified W4269-012-20 (d) 005W3254-108 . . . 1 . Wire Identified W4269-0113-12 (e) 005W3254-109 . . . 1 . Wire Identified W4269-0114-12 (e) 141W7400-43 . 1 . . . Left No.1 Window Assembly (f)(g) (h)(i)(k)(m) 141W7400-44 1 . . . . Right No.1 Window Assembly (f)(g) (h)(j)(l)(m) D-436-37 . . 2 2 . SpliceApril 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 25 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

D-436-38 . . 2 2 . Splice M39029/57-358 . . 2 2 . Socket Contact M39029/57-359 . . 2 2 . Socket Contact (a) Top Kit 005W3254-1 includes the subkits to do the wiring changes for both the left and the right side of an airplane but it includes no windows. (b) A subkit 005W3254-2 and a Window 141W7400-44 are equivalent to a top kit 005W3254-5. (c) A subkit 005W3254-3 and a Window 141W7400-43 are equivalent to a top kit 005W3254-4. (d) Wire, BMS 13-48, Type 10, Class 1, AWG 20 (e) Wire, BMS 13-48, Type 8, Class 1, AWG 12 (f) Discard the existing part. (g) This part is used in production. (h) You cannot use the existing part to replace the new or changed part. (i) As an option operators can install Left Windshield part number 141W7400-31 or 141W7400-33 with serial numbers 04xxxH or 05xxxH. (j) As an option operators can install Right Windshield part number 141W7400-32 or 141W7400-34 with serial numbers 04xxxH or 05xxxH. (k) As an option operators can install Left Windshield part number 141W7400-35 or 141W7400-41. Windshield part numbers 141W7400-35 and 141W7400-41 can be made from Windshield part numbers 141W7400-31 and 141W7400-33 with serial numbers 06339H or higher by the incorporation of Boeing Service Bulletin 777-56-0002. (l) As an option operators can install Right Windshield part number 141W7400-36 or 141W7400-42. Windshield part numbers 141W7400-36 and 141W7400-42 can be made from Windshield part numbers 141W7400-32 and 141W7400-34 with serial numbers 06339H or higher by the incorporation of Boeing Service Bulletin 777-56-0002. (m) PPG Aerospace - Transparencies Div Glass (V53117) P.O. Box 2200 1719 U.S. Highway 72 East Huntsville, AL 35811-9660 **Kit 005W3254 New Part**  **Number QTY**  **Name Notes -5 -4 -3 -2 -1** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 26 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

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**  233W8300-7A 1 Glareshield 233W8300-21A (a)(b)(c) 233W8300-20A 1 Glareshield 233W8300-22A (a)(b)(c) (a) Make the change given in this service bulletin. (b) This is the part number after the change given in this service bulletin. (c) This part is used in production.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 27 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**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. Transmit a 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 777-30-0012 R1) **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 31/2007**  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 SlingApril 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 28 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

BLANK PAGEApril 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 29 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**3. ACCOMPLISHMENT INSTRUCTIONS A. GENERAL INFORMATION**  **CAUTION:** KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **NOTE:** 1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for definition of the acronyms. 2. Obey all of the warnings and cautions given in the specified manual sections. 3. The work instructions are divided into work packages. Task-Hours and Elapsed-Hours for each package are given in Paragraph 1.G., Manpower. You can do each work package independently. 4. Unless shown differently, these dimensions and tolerances are used: — Linear dimensions are in inches — Torque limits to tighten nuts and bolts are given in 757 Structural Repair Manual, Chapter 51. 5. Refer to the 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 "as given in" are included in the instruction, the procedure in the Boeing document must be used.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 30 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

**B. WORK INSTRUCTIONS WORK PACKAGE 1 - INSPECTION OF THE LEFT NUMBER 1 WINDOW**  **WARNING:** BEFORE YOU DO MAINTENANCE ON THE WINDOW HEAT SYSTEM, OPEN THE WINDOW HEAT CIRCUIT BREAKERS. IF THESE CIRCUIT BREAKERS ARE NOT OPEN, YOU CAN GET AN ELECTRICAL SHOCK WHEN YOU TOUCH THE TERMINAL. 1. Open the circuit breakers shown below and attach DO-NOT-CLOSE tags to them:

2. Do an inspection of the left number 1 window as given in Figure 5. 3. If the left number 1 window is not in a serviceable condition, replace it before the subsequent revenue flight. Refer to 777 AMM 56-11-01 as an accepted procedure. If the existing window is replaced with one of the same type, it will be necessary to do this inspection within 500 flight hours. Windshields in serviceable condition can continue to be used with inspections every 6000 flight hours, or until the work given in Work Package 3 is done. 4. Remove the DO-NOT-CLOSE tags and close the circuit breakers shown below: **Panel Position Name Circuit Breaker** P110 M26 WHCU BITE 1L C30613 P100 E01 or E02 WDO HTR 1L C30301 P110 F03 WDO HT BACKUP 1L C30415

**Panel Position Name Circuit Breaker** P110 M26 WHCU BITE 1L C30613 P100 E01 or E02 WDO HTR 1L C30301 P110 F03 WDO HT BACKUP 1L C30415April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 31 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**WORK PACKAGE 2 - INSPECTION OF THE RIGHT NUMBER 1 WINDOW WARNING:**  BEFORE YOU DO MAINTENANCE ON THE WINDOW HEAT SYSTEM, OPEN THE WINDOW HEAT CIRCUIT BREAKERS. IF THESE CIRCUIT BREAKERS ARE NOT OPEN, YOU CAN GET AN ELECTRICAL SHOCK WHEN YOU TOUCH THE TERMINAL. 1. Open the circuit breakers shown below and attach DO-NOT-CLOSE tags to them:

2. Do an inspection of the right number 1 window as given in Figure 6. 3. If the right number 1 window is not in a serviceable condition, replace it before the subsequent revenue flight. Refer to 777 AMM 56-11-01 as an accepted procedure. If the existing within 500 flight hours. Windshields in serviceable condition can continue to be used with inspections every 6000 flight hours, or until the work given in Work Package 4 is done. 4. Remove the DO-NOT-CLOSE tags and close the circuit breakers shown below: **Panel Position Name Circuit Breaker** P210 L08 WHCU BITE 1R C30616 P200 B04 or D11 WDO HTR 1R C30300 P210 C12 WDO HT BACKUP 1R C30414

**Panel Position Name Circuit Breaker** P210 L08 WHCU BITE 1R C30616 P200 B04 or D11 WDO HTR 1R C30300 P210 C12 WDO HT BACKUP 1R C30414April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 32 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

**WORK PACKAGE 3 - REPLACEMENT OF THE LEFT NUMBER 1 WINDOW AND CHANGES TO THE RELATED WIRE BUNDLE**  **WARNING:** REMOVE ELECTRICAL POWER FROM THE WINDOW HEAT SYSTEM BEFORE YOU REMOVE THE WINDOWS. IF POWER TO THE WINDOW HEAT SYSTEM IS ON, YOU CAN GET AN ELECTRICAL SHOCK IF YOU TOUCH ELECTRICAL CONTACTS ATTACHED TO THE WINDOW. AN ELECTRICAL SHOCK CAN CAUSE INJURY TO PERSONS. 1. Remove electrical power from the flight compartment window heat systems. Refer to 777 AMM 56-11-01 as an accepted procedure. 2. Remove the left number 1 window. Use the windshield handling sling, A56001-2. Refer to 777 AMM 56-11-01 as an accepted procedure. 3. Cut the bulb seal for the left number 1 window as given in Figure 1. 4. Change the window heat wiring for the left number 1 window as given in Figure 2. 5. Install the left number 1 window 141W7400-43. Use the windshield handling sling, A56001-2. Refer to 777 AMM 56-11-01 as an accepted procedure. 6. Restore electrical power to the flight compartment window heat systems. Refer to 777 AMM 56-11-01 as an accepted procedure. 7. Do the Window Heat Control System - Operational Test as given in 777 AMM 30-41-00. 8. Put the airplane in a serviceable condition.April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 33 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**WORK PACKAGE 4 - REPLACEMENT OF THE RIGHT NUMBER 1 WINDOW AND CHANGES TO THE RELATED WIRE BUNDLE**  **WARNING:** REMOVE ELECTRICAL POWER FROM THE WINDOW HEAT SYSTEM BEFORE YOU REMOVE THE WINDOWS. IF POWER TO THE WINDOW HEAT SYSTEM IS ON, YOU CAN GET AN ELECTRICAL SHOCK IF YOU TOUCH ELECTRICAL CONTACTS ATTACHED TO THE WINDOW. AN ELECTRICAL SHOCK CAN CAUSE INJURY TO PERSONS. 1. Remove electrical power from the flight compartment window heat systems. Refer to 777 AMM 56-11-01 as an accepted procedure. 2. Remove the right number 1 window. Use the windshield handling sling, A56001-2. Refer to 777 AMM 56-11-01 as an accepted procedure. 3. Cut the bulb seal for the right number 1 window as given in Figure 3. 4. Change the window heat wiring for the right number 1 window as given in Figure 4. 5. Install the right number 1 window 141W7400-44. Use the windshield handling sling, A56001-2. Refer to 777 AMM 56-11-01 as an accepted procedure. 6. Restore electrical power to the window heat systems for the flight compartment. Refer to 777 AMM 56-11-01 as an accepted procedure. 7. Do the Window Heat Control System - Operational Test as given in 777 AMM 30-41-00. 8. Put the airplane in a serviceable condition.**FIGURE 1: CUT THE BULB SEAL FOR THE LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 34 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

**FIGURE 1: CUT THE BULB SEAL FOR TH E LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW** 

FWD GLARESHIELD

A SEE

2365443

**(SHEET 1 OF 2) FIGURE 1: CUT THE BULB SEAL FOR THE LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW**  April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 35 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure. **STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION:**  DO NOT CUT THE STRUCTURE BELOW THE BULB SEAL. THE WINDOW SILL IS A HIGH MOISTURE AREA AND MOISTURE CAN CAUSE CORROSION IF THE FINISH IS DAMAGED. DAMAGE TO THE FINISH MUST BE REPARED.

1 Cut Bulb Seal 233W8300-11 - 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 20-43-02 as accepted procedures. 2 Identify Glareshield 233W8300-21A - (a) (a) Part mark with new part number. Rubber-Stamp or Hand Write. 12 characters per inch. Use abrasive resistance ink. Refer to SOPM 20-50-10 as an accepted procedure. 

### BULB SEAL



### A 1

1.20 1.40 FWD384851

**(SHEET 2 OF 2) FIGURE 2: WIRING CHANGE FOR THE**  **LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 36 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

**FIGURE 2: WIRING CHANGE FOR THE LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW** 



### FLIGHT COMPARTMENT

FWD INBD J13 J5 J1

J15 W4123 AREA SPLICE359711

**(SHEET 1 OF 3) FIGURE 2: WIRING CHANGE FOR THE LE**  **FT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 37 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

2005B-12 2005R-12 0002-20 1001-20

SM9 SM4 SM3

SM10

0111-20

0112-20

0113-12

0114-12 J15

J13

J5

J1

STA 160, WL 250, LBL 15 B30101 WINDOW 1-LEFT STA 160, WL 250, LBL 15 B30101 WINDOW 1-LEFT

D30108 B-A

B-B D30106 J15

J13 =1

=1

D30105

D30104

D30101 E-A =1

=1

=1 E-B

E-C J5

J4

J1 1

1

2

2 

# W4123

3

4

5

6 8

8 7

7



### DELETED WIRE OR FORMER ROUTING ADDED WIRE OR NEW ROUTING

EXISTING WIRE REFERENCE: WIRING DIAGRAM 30-41-11W88286

**(SHEET 2 OF 3) FIGURE 2: WIRING CHANGE FOR THE**  **LEFT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 38 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. **NOTE:** Use the parts supplied in kit 005W3254-3 or equivalent.
**FLAG NOTE NAME IDENTIFICATION QTY MORE DATA**  1 Splice D-436-37 2 Refer to Standard Wiring Practices Manual SWPM 20-30-12 as an accepted procedure. 2 Splice D-436-38 2 Refer to SWPM 20-30-12 as an accepted procedure. 3 Wire Lacing Tape 005W3254-101 BMS 13-54, Type 3, Class 1, Red 1 (a) or optional BACS38K5C Tie Strap (c)
4 Wire Lacing Tape 005W3254-102 BMS 13-54, Type 3, Class 1, Red 1 (a) or optional BACS38K5C Tie Strap (c)
5 Wire Lacing Tape 005W3254-103 BMS 13-54, Type 3, Class 1, Red 1 (b) or optional BACS38K5C Tie Strap (c)
6 Wire Lacing Tape 005W3254-104 BMS 13-54, Type 3, Class 1, Red 1 (b) or optional BACS38K5C Tie Strap (c)
7 Socket Contact M39029/57-358 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. 8 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. (a) BMS 13-48, Type 10, Class 1, AWG 20 (b) BMS 13-48, Type 8, Class 1, AWG 12 (c) Red is for left channel separation. Refer to SWPM 20-10-19 as an accepted procedure.

**(SHEET 3 OF 3) FIGURE 3: CUT THE BULB SEAL FOR TH**  **E RIGHT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 39 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**FIGURE 3: CUT THE BULB SEAL FOR THE RIGHT NUMBER 1 FLIGHT COMPARTMENT WINDOW** 

FWD GLARESHIELD

A SEE 2365437

**(SHEET 1 OF 2) FIGURE 3: CUT THE BULB SEAL FOR TH**  **E RIGHT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 40 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure. **STEP TASK NAME IDENTIFICATION QTY MORE DATA CAUTION:**  DO NOT CUT THE STRUCTURE BELOW THE BULB SEAL. THE WINDOW SILL IS A HIGH MOISTURE AREA AND MOISTURE CAN CAUSE CORROSION IF THE FINISH IS DAMAGED. DAMAGE TO THE FINISH MUST BE REPARED.

1 Cut Bulb Seal 233W8300-12 - 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. 2 Identify Glareshield 233W8300-22A - (a) (a) Part mark with new part number. Rubber-Stamp or Hand Write. 12 characters per inch. Use abrasive resistance ink. Refer to SOPM 20-50-10 as an accepted procedure. 

### A 1 BULB SEAL

1.20 1.40 FWD384883

**(SHEET 2 OF 2) FIGURE 4: WIRING CHANGE FOR THE RI**  **GHT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 41 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

**FIGURE 4: WIRING CHANGE FOR THE RI GHT NUMBER 1 FLIGHT COMPARTMENT WINDOW** 



### FLIGHT COMPARTMENT

INBD

FWD J13 SPLICE AREA

W4269 J1

J15

J5W86527

**(SHEET 1 OF 3) FIGURE 4: WIRING CHANGE FOR THE RIGHT NUMBER 1 FLIGHT COMPARTMENT WINDOW**  April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 42 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

D30206

D30208

D30205

D30204

D30201

STA 160, WL 250, RBL 15 B30201 WINDOW 1-RIGHT STA 160, WL 250, RBL 15 B30201 WINDOW 1-RIGHT J1 J4 J5

E-C E-B

=1 =1 =1 E-A =1 =1

J13 J15

B-B B-A

J1 J5 J13 J15

0114-12 0113-12 0112-20 0111-20 SM10 SM3

SM4

SM9 1001-20

0002-20

2005R-12

2005B-12 

# W4269

7 7

8 8

6 5 4 3 2 2 1 1



### REFERENCE: WIRING DIAGRAM 30-41-12

DELETED WIRE OR FORMER ROUTING ADDED WIRE OR NEW ROUTING

EXISTING WIREW86528

**(SHEET 2 OF 3) FIGURE 4: WIRING CHANGE FOR THE RI**  **GHT NUMBER 1 FLIGHT COMPARTMENT WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 43 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure. **NOTE:** Use the parts supplied in kit 005W3254-2 or equivalent.
**FLAG NOTE NAME IDENTIFICATION QTY MORE DATA**  1 Splice D-436-37 2 Refer to Standard Wiring Practices Manual SWPM 20-30-12 as an accepted procedure. 2 Splice D-436-38 2 Refer to SWPM 20-30-12 as an accepted procedure. 3 Wire Lacing Tape 005W3254-106 BMS 13-54, Type 3, Class 1, Green 1 (a) or optional BACS38K5F Tie Strap (c)

4 Wire Lacing Tape 005W3254-107 BMS 13-54, Type 3, Class 1, Green 1 (a) or optional BACS38K5F Tie Strap (c)

5 Wire Lacing Tape 005W3254-108 BMS 13-54, Type 3, Class 1, Green 1 (b) or optional BACS38K5F Tie Strap (c)

6 Wire Lacing Tape 005W3254-109 BMS 13-54, Type 3, Class 1, Green 1 (b) or optional BACS38K5F Tie Strap (c)

7 Socket Contact M39029/57-358 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. 8 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. (a) BMS 13-48, Type 10, Class 1, AWG 20 (b) BMS 13-48, Type 8, Class 1, AWG 12 (c) Green is for right channel separation. Refer to SWPM 20-10-19 as an accepted procedure.

**(SHEET 3 OF 3) FIGURE 5: INSPECTION OF AN ELECTRI**  **CAL CONNECTION ON THE LEFT NUMBER 1 WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 44 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

**FIGURE 5: INSPECTION OF AN ELECTRICAL CONNECTION ON THE LEFT NUMBER 1 WINDOW** 



### FLIGHT COMPARTMENT

INBD

FWD 3

1 2 3 SCREW J13

J5

CONNECTOR BLOCK, TERMINAL LUG J4 J15 J1 W4123498760

**(SHEET 1 OF 2) FIGURE 5: INSPECTION OF AN ELECTRI**  **CAL CONNECTION ON THE LEFT NUMBER 1 WINDOW** April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 45 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

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 - 1 at the J5 connection Connector - 1 Wiring Wire bundle W4123 1 **NOTE:** If there is a melted terminal, black marks, or discoloration, the window must be replaced. **NOTE:** If there is damage to the wiring it must be repaired. Refer to Standard Wiring Practices Manual SWPM 20-10-13 as an accepted procedure.

2 Inspect Lug - 1 to make sure it is a tight connection. **NOTE:** If the lug at the terminal moves with light manual pressure, then the screw that attaches it must be tightened. There are three 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 part number of the correct screw is NAS1802-3-11. **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 Turn Screw - 1 to 25 to 30 inch pounds of torque. Refer to Standard Overhaul Practices Manual SOPM 20-43-03 as an accepted procedure. Inspect Lug 1 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, the window must be replaced.

**(SHEET 2 OF 2) FIGURE 6: INSPECTION OF AN ELECTRICAL CONNECTION ON THE RIGHT NUMBER 1 WINDOW**  April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 46 of 47 

### BOEING SERVICE BULLETIN 777-30-0012

**FIGURE 6: INSPECTION OF AN ELECTRICAL CONNECTION ON THE RIGHT NUMBER 1 WINDOW** 



### FLIGHT COMPARTMENT

1
FWD INBD 3 3 2 W4269

TERMINAL CONNECTOR BLOCK, J1

SCREW LUG

J5 J13 J15 J4499019

**(SHEET 1 OF 2) FIGURE 6: INSPECTION OF AN ELECTRICAL CONNECTION ON THE RIGHT NUMBER 1 WINDOW**  April 07, 2004 Revision 2: December 19, 2007 777-30-0012 BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 47 of 47 

### BOEING SERVICE BU **LLETIN 777-30-0012**

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 - 1 at the J5 connection Connector - 1 Wiring Wire bundle W4269 1 **NOTE:** If there is a melted terminal, black marks, or discoloration, the window must be replaced. **NOTE:** If there is damage to the wiring it must be repaired. Refer to Standard Wiring Practices Manual SWPM 20-10-13 as an accepted procedure.

2 Inspect Lug - 1 to make sure it is a tight connection. **NOTE:** If the lug at the terminal moves with light manual pressure, then the screw that attaches it must be tightened. There are three 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 part number of the correct screw is NAS1802-3-11. **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 Turn Screw - 1 to 25 to 30 inch pounds of torque. Refer to Standard Overhaul Practices Manual SOPM 20-43-03 as an accepted procedure. Inspect Lug 1 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, the window must be replaced.

**(SHEET 2 OF 2)**