Technical Training Manual for Boeing 737-600/-700/-800/-900 Windows

BOSTONAIR Technical Training Manual

Boeing 737-600/-700/-800/-900 Table of Contents

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 TABLE OF CONTENTS 1 Windows - introduction - 4 - 1.1 General 4 - 2 Flight compartment windows - 6 - 2.1 General Description. - 6 - 2.2 Interface. - 6 - 2.3 Location. - 7 - 2.4 Physical Description/Features - 7 - 2.5 Flight Compartment Window No. 1. - 9 - 2.5.1 General - 9 - 2.5.2 Training Information Point. - 9 - 2.6 Flight Compartment Window No. 3. 11 - 2.7 Flight Compartment Windows No. 4 and 5. 12 - 2.7.1 General 12 - 2.8 Flight Compartment Window No. 2. 13 - 2.8.1 Purpose 13 - 2.8.2 Physical Description 13 - 2.8.3 Functional Description 14 - 2.8.4 Normal Operation 14 - 2.8.5 Emergency Operation 14 - 3 Passenger compartment windows 16 - 3.1 Passenger windows 16 - 3.1.1 General 16 - 3.1.2 Location - 16 - 3.1.3 Physical Description/Features - 16 - 3.1.4 Maintenance Practices. 16 3.1.5 Seal leak detection - 18 - 3.1.6 Edge damage 19 - 3.1.7 Window concavity 20 3.2 Door mounted windows - 21 - 3.2.1 General 21 - 3.3 Emergency hatch window 22 - 3.3.1 General 22 - 3.3.2 Location 22 - Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 1 -

List of Figures

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 LIST OF FIGURES Figure 1: Windows .... ...... .... -5 - Figure 2: Flight compartment windows - 6 - Figure 3: Flight compartment windows construction - 8 - Figure 4: Window number 1 - 9 - Figure 5: Window 1 installation 10 - Figure 6: Window number 3 11 - Figure 7: Windows number 4 & 5 12 - Figure 8: Window number 2 13 - Figure 9: Openable window number 2 15 - Figure 10: Passenger window installation 17 - Figure 11: Seal leak detection 18 - Figure 12: edge damage 19 - Figure 13: Window concavity 20 - Figure 14: Door mounted window 21 Figure 15: Emergency hatch window 22 - Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 2 -

Abbreviations and Acronyms

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 ABBREVIATIONS AND ACRONYMS -NONE- Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 3 -

Aircraft Window Introduction

General Window Types

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 1 Windows - introduction 1.1 General These are the types of windows on the airplane: · Flight compartment windows (fixed and sliding) · Passenger compartment windows · Emergency exit windows · Door-mounted windows. All the windows can hold cabin pressurization loads and have fail safe properties. Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 4 -

Boeing 737 Window Diagram

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 EMERGENCY air OPEN EMERGENCY EXIT HATCH WINDOW PASSENGER COMPARTMENT WINDOWS DOOR-MOUNTED WINDOW FLIGHT COMPARTMENT WINDOWS OD IATA BOEING 737-600 BOEING 737 Figure 1: Windows Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 5 -

Flight Compartment Windows Overview

General Description of Flight Compartment Windows

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 2 Flight compartment windows 2.1 General Description. There are ten windows in the flight compartment. There are five left (L) windows and five right (R) windows. Right compartment windows No. 1, 3, 4, and 5 are fixed and do not open. Window No. 2 is a sliding window that opens. 2.2 Interface. Some flight compartment windows get heat from the window anti-ice system. NO. 4L NO. 4R NO. 5L\ NO. 5R NO. 2L NO. 2R NO. 3R NO. 3L NO. 1L NO. 1R FLIGHT COMPARTMENT WINDOWS Figure 2: Flight compartment windows Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 6 -

Flight Compartment Window Location and Features

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 2.3 Location There are ten windows symmetrically located around the flight compartment. Windows No. 1, 3, 4 and 5 are fixed in place. Window No. 2 is a sliding window, mounted on tracks, to permit ventilation and communication on the ground. 2.4 Physical Description/Features The construction of control cabin windows No. 1 and No. 2 consists of a glass pane laminated to each side of a polyvinyl butyral (vinyl) interlayer or core. The inner glass pane is the thicker of the two and is the primary load carrying member. The vinyl interlayer acts as the "fail-safe" load carrying member and prevents the window from shattering if the inner pane should break. The outer pane has no structural significance, but provides rigidity and a hard, scratch resistant surface. A thin strip of parting medium is laminated around the window edges between the vinyl interlayer and each glass pane. This is to prevent edge chipping of the glass under conditions of differential expansion and contraction. A conductive coating of indium oxide applied on the inner face of the outer glass pane permits electrical heating for anti-icing and defogging. The construction of No. 3 window consists of two stretched acrylic panes separated by a phenolic spacer. The spacer is attached to the perimeter of the panes by pressure sensitive tape which also acts as an air seal. The spacer provides an insulation cavity which prevents fogging on the inner surface of the windows. There is a small hole in the upper forward corner of the inner pane. This hole must be open at all times to allow pressure in the air space to equalize with pressure in the cabin. Windows No. 4 and No. 5 are similar in construction in that both consist of a glass pane laminated to each side of a polyvinyl butyral core. A conductive film applied on the outer face of the inner glass permits electrical heating for anti-icing and defogging. No. 4 window, however, has an additional vinyl layer laminated to the inboard surface of the inner pane. A cast acrylic sheet 15 laminated to the additional vinyl layer. These additional layers prevent glass from scattering throughout the cabin in the event of bird impact. The additional layers are of no structural importance. A thin parting medium is laminated around the window edges between the vinyl interlayers and each glass pane. This is to prevent edge chipping of the glass under conditions of differential expansion and contraction. The window seals which are used on the flight compartment windows consist of fixed window pressure seals, which are used on windows No. 1, 3, 4, and 5, and the sliding window pressure seals installed on windows No. 2. The primary purpose of the two types of pressure seals is to prevent cabin pressurization leakage around the windows when the airplane is pressurized. The sealants that are used on the windows prevent moisture penetration, water entrapment, and provide aerodynamic flushness of the outer windowpane with the window frame. Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 -7 -

Flight Compartment Window Construction

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 MATERIAL TYPICAL CROSSECTION CAST ACRYLIC VINYL GLASS 4 VINYL CONDUCTIVE COATING GLASS OUTSIDE 5 VINYL GLASS OUTSIDE GLASS VINYL CONDUCTIVE COATING GLASS OUTSIDE GLASS VINYL GLASS CONDUCTIVE COATING OUTSIDE GLASS - 2 VINYL CONDUCTIVE COATING GLASS OUTSIDE Figure 3: Flight compartment windows construction Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 8 - 3 1 GLASS CONDUCTIVE COATING

Flight Compartment Window No. 1

General Description of Window No. 1

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 2.5 Flight Compartment Window No. 1. 2.5.1 General The No. 1 window is pressure sealed on installation by means of a gasket- like, molded-in-place rubber seal. The beaded silicon rubber seal surface mates with the window frame to ensure an effective pressure and moisture- tight seal. The pressure seal is an integral part of the window assembly and, in combination with a formed stainless steel Z-channel strip, is bonded to the periphery of the windshield glass. Removal and installation should not be attempted without consulting the current Maintenance Manual. Replacement windows are supplied with the necessary parts for installation and with both sides of the pane covered with a protective coating. To remove a No. 1 window, not only must the window fasteners be removed but also any trim panels, crash padding, windshield wipers, the light shield (P7 panel), sunshade support rod, drain tube clamps, and drain pan must also be removed. Pressure is applied to the window from the outside, pushed into the cabin, and removed. Some general precautions to observe include: . Use only non-magnetic bolts along the top, bottom and forward edges of the window because of the proximity to the standby compass. . Use a staggered sequence, diagonally back and forth across the window, to tighten each nut to the correct torque value. Damage to the window may result if the correct torque is exceeded. Consult the Maintenance Manual for the proper torque values and a recommended staggered sequence. 2.5.2 Training Information Point. Use proper methods when you clean the windows to prevent damage. Use an isopropanol and water mixture on the external surface. Use a mild soap and water mixture or an isopropanol and water mixture on the internal surface. Warning: be careful when you do work on the window no. 1. The output voltage of the autotransformer is 250-350 volts. This can cause injury to persons. NOEING 777 Figure 4: Window number 1 Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 9 -

Window No. 1 Installation Diagram

BOSTONAIR Technical Training BOSTONAIR TECHNICAL TRAINING LIMITED UK.147.0085 TECHNICAL TRAINING MANUAL BOEING 737-600/-700/-800/-900 WINDOW FRAME POST WINDOW NO. 1 ASSEMBLY SEE A WINDOW FRAME WINDOW NO. 1 FWD STAINLESS STEEL Z-CHANNEL (BONDED IN PLACE) ALUMINUM SPACER 8 RETAINING BOLT ETHYLENE PROPYLENE O-RING AERODYNAMIC SMOOTHER - ALUMINUM FLAT WASHER NYLON CORD B WINDOW FRAME WIRE CLAMP PRESSURE SEAL (BONDED IN PLACE) SEALANT HEX HEAD SELF LOCKING NUT A Z-CHANNEL FASTENER INSTALLATION ON TOP, BOTTOM AND FORWARD EDGE OF WINDOW NO. 1 SEALANT WIRE MESH- (NOT ON ALL AIRPLANES) NO. 1 WINDOW Z-CHANNEL PRESSURE SEAL INNER SURFACE OF GLASS VARIES ACCORDING TO LOCATION WINDOW FRAME NYLON CORD BOLT, 100° HEAD PHILLIPS RECESS A-A SPACER NOTE: RETAINING WINDOW FRAME REMOVED FOR CLARITY B-B Figure 5: Window 1 installation Maintenance Course B1/B2 ATA 56 WINDOWS Issue 4 - October 2024 - 10 - & AIRPLANE