Cascade Aviation Services, Inc. · The Boeing 737 aircraft will have its eyebrow windows (cockpit windows #4 and 5) replaced by window blanks per Cascade Aviation Services Engineering

Cascade Aviation Services, Inc.

Document Identification:

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

Document No.

05CAS469-D30

Project: Eyebrow Window Replacement, Boeing 737 Series Airplanes

STC No.:

ST01630SE

Customer:

N/A

Revision Date

NEW 8/25/05

A 9/8/05

B 8/14/06

C 10/19/06

D 11/2/06

E 6/25/07

F 4/27/09

Prepared by: Edgar Graudins Date: 8/25/05 original revision signed by

Approved by: Paul Kingswell Date: 8/25/05 original revision signed by


Instructions for Continued Airworthiness Document: 05CAS469-D30

Revision: Page:

F II

REVISION PAGE

Revision Description Date Approval

New

Original Release.

8/25/05

See Cover

A

Page 2. Sec 7.0 Added hourly inspection

intervals.

9/8/05

Prepared

P. Kingswell

Checked:

E. Graudins

B

Cover page: changed FAA project number to

STC number.

Page 2: corrected W&B numbers in section 8.0.

Page 3: added addition window blank part

numbers to Table 2.

8/14/06

Prepared

E. Graudins Checked:

B. Norman

C

Revised section 7.0 to clarify the inspection

intervals.

10/19/06

Prepared


P. Vallins

D

Revised section 7.0 to incorporate inspection

intervals suggested by AEG.

11/2/06

Prepared


P. Vallins

E

Page 2: Clarified DET requirements. Updated

weight info in Table 1.

Page 3: Updated part numbers in Table 2.

6/25/07

Prepared


P. Vallins

F

Updated section 7.0 with new inspection

interval definitions.

Added new sections 8.0 and 9.0 for Part 26

compliance.

4/27/09

Prepared


B. Norman



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F III

LIST OF ACTIVE PAGES Page Revision Added Pages

Section Number Level Page Revision Page Revision Page Revision

I (cover)

II

III

IV

1

2

3

4

5

6

7

F

F

F

F

New

F

F

F

F

F

F

8

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TABLE OF CONTENTS

REVISION PAGE.......................................................................................................................................................II

LIST OF ACTIVE PAGES ...................................................................................................................................... III

TABLE OF CONTENTS ......................................................................................................................................... IV

1.0 SCOPE....................................................................................................................................................................1

2.0 PURPOSE...............................................................................................................................................................1

3.0 APPLICABILITY..................................................................................................................................................1

4.0 ABBREVIATIONS................................................................................................................................................1

5.0 DESCRIPTION OF MODIFICATION ...............................................................................................................1

6.0 REFERENCES.......................................................................................................................................................1

7.0 INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE...............................................................2

8.0 FATIGUE AND DAMAGE TOLERANCE.........................................................................................................2

9.0 ELECTRICAL WIRING INTERCONNECTION SYSTEM ............................................................................2

10.0 WEIGHT AND BALANCE ................................................................................................................................3

11.0 MATERIALS AND TOOLS...............................................................................................................................3

12.0 AIRWORTHINESS LIMITATIONS.................................................................................................................4

13.0 DOCUMENT CONTROL...................................................................................................................................4

14.0 FIGURES..............................................................................................................................................................5

15.0 CHECKLIST........................................................................................................................................................6



Revision: Page:

New 1

1.0 SCOPE

The scope of this document is to provide the necessary information for the maintenance and

continued airworthiness of components installed on Boeing 737 series aircraft.

2.0 PURPOSE

The purpose of this document is to provide maintenance and continued airworthiness data in

accordance with CFR Part 25.1529 and Appendix H.

3.0 APPLICABILITY

This document is applicable to all models of 737 aircraft (737-100, -200, -200C, -300, -400, -500,

-600, -700, -700C, -800, -900).

4.0 ABBREVIATIONS

AEG Aircraft Evaluation Group

FAA Federal Aviation Administration

CFR Code of Federal Regulations

ICA Instructions for Continued Airworthiness

5.0 DESCRIPTION OF MODIFICATION

A Supplemental Type Certificate approves this modification.

The Boeing 737 aircraft will have its eyebrow windows (cockpit windows #4 and 5) replaced by

window blanks per Cascade Aviation Services Engineering Drawing 05CAS469201 or

05CAS469203.

The existing eyebrow windows will be removed. New window blanks manufactured by Cascade

Aviation will be installed in their place. The surrounding airframe will not be affected, and the

attachment of the window blanks will be identical to the OEM window installation. The window

heating circuit will be disabled. See Figure 1 for a typical window blank installation.

6.0 REFERENCES

Boeing 737 Aircraft Maintenance Manual (AMM).

Boeing 737 Structural Repair Manual (SRM).



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F 2

7.0 INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE

Operator to perform a General Visual Inspection (GVI) of the window blanks, support structure,

and attaching hardware for damage or fatigue cracking within every 4,500 flight cycles (this can

be accomplished during the airline’s equivalent of a C-check). Removal or disassembly of the

window blanks is not required for this inspection.

Operator to perform a Detailed Inspection (DET) of the window blanks, support structure, and

attaching hardware for damage or fatigue cracking within 30,000 flight cycles of the initial

installation (this can be accomplished during the airline’s equivalent of a D-check, typically every

24,000 flight cycles), and reinspected within every 30,000 cycles after that. In addition to normal

inspection procedures, detailed inspection of the window blank also includes disassembly of the

window blank and inspection of the inner surface of the window blank for cracks or corrosion

(disassembly requires removal of the decorative cover plate and insulation blanket). Window

blank may be left in place if cover and insulation can be removed without removal of window

blank from aircraft frame. All surfaces of the window blanks should be inspected visually, and as

required, using a magnifying glass.

If the inspection intervals noted above differ from those identified in AMM supplement

05CAS469-D82, the inspection intervals of this ICA document take precedence.

All primary structure attachments were provisioned by Boeing and are part of the TC. They are

covered by the Boeing Maintenance Manual and Structural Repair Manual. Cosmetic or structural

damage to the window blanks may be repaired or the blanks replaced per Aircraft Maintenance

Manual Supplement 05CAS469-D82.

8.0 FATIGUE AND DAMAGE TOLERANCE

The window frames that the window blanks interface with are considered Fatigue Critical

Baseline Structure (FCBS). Since the window blanks have the same interface loads as the OEM

windows, the existing Boeing inspection instructions and intervals for the surrounding airframe

are unaffected by the window blank installation.

The window blanks are part of the pressure shell and are therefore subject to cyclic loading.

Although they are considered Fatigue Critical Alternation Structure (FCAS), the robustness of the

blanks results in a low probability of failure from fatigue cracking. The window blanks should be

inspected per section 7.0 above.

9.0 ELECTRICAL WIRING INTERCONNECTION SYSTEM

The eyebrow window blank replacement does not install any new wiring that would require

EWIS-ICA instructions. This modification does not affect the existing Boeing 737 EWIS-ICA

document.



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F 3

10.0 WEIGHT AND BALANCE

The weight change to a 737 aircraft from the eyebrow window replacement is summarized in the

following table for all models of 737 aircraft. For detailed weight & balance data see report

05CAS469-D20.

Table 1: Weight change to 737 aircraft Weight Change (lbs) Kit Number Note

-2.2 05CAS469101-1 (or -3) Window blank installation (with integral insulation and cover plate)

-1.1 05CAS469101-1 (or -3) & 05CAS469102-1

Window blank installation with optional insulation upgrade kit

-2.2 05CAS469103-1 Window blank installation (with separate insulation and cover plate)

11.0 MATERIALS AND TOOLS

No special materials or tools are required to maintain or inspect the window blanks.

Table 2: The following parts can be repaired or replaced, as needed: 05CAS469401-1 LH window #4 blank assy

05CAS469401-2 RH window #4 blank assy

05CAS469401-3 LH window #4 blank assy










05CAS469510-1 Insulated cover LH #4

05CAS469510-2 Insulated cover RH #4

05CAS469510-3 Insulated cover LH #5

05CAS469510-4 Insulated cover RH #5

141A4841-XX Nut plate assemblies*

BACB30NN4K18 Bolt*

05CAS469507-101 Gasket

05CAS469508-101 Gasket

* Parts identical to OEM window installation. Replacement parts are obtained from Boeing or

any supplier of Boeing spares.



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12.0 AIRWORTHINESS LIMITATIONS

The Airworthiness Limitations section is FAA approved and specifies maintenance required

under Secs. 43.16 and 91.163 of the Federal Aviation Regulations unless an alternative program

has been FAA approved.

There are no airworthiness limitations associated with this Supplemental Type Certificate.

13.0 DOCUMENT CONTROL

Cascade Aviation Services’ Document Control center will distribute supplements for all affected

aircraft manuals to end users. End users will be updated with the latest revision of all

supplements, as they are released. Updated manuals will be supplied by mail, email, website, or

other means requested by the customer.



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F 5

14.0 FIGURES

FIGURE 1: Window #4 (LH) CAS Installation

New Window Blank

Bolt

Nut-plate assembly

O-ring strip (part of nut-plate assembly)

Nut-plate (part of nut-plate assembly)

Spacer



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F 6

15.0 CHECKLIST

Part 25, Appendix H Requirements CHECKLIST FOR 05CAS469-D30

Regulation Requirement Reference Coverage

25.1(c) A program in manual that shows how changes to the ICA

made by the applicant will be distributed

05CAS469-D30

25.2(a) ICAW in the form of a manual or manuals in a practical

arrangement

05CAS469-D30

25.3(a)(2) A description of the aircraft and its installations,

Its Engines and its systems

Its propellers and its systems

Its systems and installations, appliances and its systems

and installations.

737 AMM

N/A

N/A

Windows 4 and 5 only:

05CAS469401,

05CAS469402,

05CAS469201.

25.3(a)(3) Basic control and operating information describing how

the aircraft components and systems are controlled and

how the aircraft components and systems are operated

including any special limitations.

737 AMM

25.3(a)(4) Servicing information which cover details regarding

servicing points, capacities of tanks, capacities of

reservoirs, types of fluids used, and pressures applicable

to various systems

N/A

25.3(a)(4) Location of access panels for inspection and servicing N/A

25.3(a)(4) Servicing information that covers details regarding

location and lubrication points, and the lubricant used

N/A

25.3(a)(4) Equipment required for servicing N/A

25.3(a)(4) Tow instructions and limitations N/A

25.3(a)(4) Mooring Information N/A

25.3(a)(4) Jacking Information N/A

25.3(a)(4) Leveling Information N/A

25.3(b)(1) Scheduling information for each part of the aircraft that

provides the recommended periods, at which they should

be cleaned, inspected, adjusted, tested, lubricated, and the

work recommended at these periods.

05CAS469-D30

25.3(b)(1)

Scheduling information for the aircraft’s engine that

provides the recommended period, at which they should

be cleaned, inspected, adjusted, tested, lubricated and the


N/A

25.3(b)(1)

Scheduling information for the aircraft’s Auxiliary Power

Unit (APU) that provides the recommended period at

which they should be cleaned, inspected, adjusted, tested,

N/A



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F 7


lubricated and the work recommended at these periods.

25.3(b)(1) Scheduling information for the aircraft’s propellers that

provides the recommended period at which they should



N/A

25.3(b)(1) Scheduling information for the aircraft’s accessories that




05CAS469-D30

25.3(b)(1) Scheduling information for the aircraft’s instruments that




N/A

25.3(b)(1) Scheduling information for the aircraft’s equipment that

provides the recommended period, at which they should



N/A

25.3(b)(1) The degree of inspection for each part of the aircraft and

its engines, auxiliary power unit, propellers, accessories,

instruments and equipment.

ACCESSORIES ONLY

737 AMM

25.3(b)(1) The applicable wear tolerances N/A

25.3(b)(1) The applicant may refer to an accessory, instrument, or

equipment manufacturer as the source of its information

if applicant shows that the item has an exceptionally high

degree of complexity requiring specialized maintenance

techniques, test equipment, or expertise

N/A

25.3(b)(1) The recommended overhaul periods and necessary cross

references to the Airworthiness Limitation Section

N/A

25.3(b)(1) An inspection program that includes the frequency and

extent of the inspection necessary to provide for the

Continued Airworthiness of the aircraft.

05CAS469-D30

25.3(b)(2) Troubleshooting information, describing problem,

malfunctions, how to recognize those malfunctions and

the remedial action for those malfunctions.

N/A

25.3(b)(3) Information describing the order and method of removing

and replacing engines with any necessary precautions to

be taken.

N/A

25.3(b)(3) Information describing the order and method of removing

and replacing parts with any necessary precautions to be

taken.

737 AMM

25.3(b)(4) Other general procedural instructions including storage

limitations and procedures for testing systems during

N/A



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F 8


ground running, making symmetry checks, weighing and

determining the center of gravity, lifting, and shoring.

25.3(c) Diagrams of structural plates and information needed to

gain access for inspections when access plates are not

provided.

N/A

25.3(d) Details for the application of special inspection

techniques including radiographic and ultrasonic testing

where such processes are specified.

N/A

25.3(e) Information needed to apply protective treatment to

structure after inspection.

N/A

25.3(f) All data relative to structural fasteners such as

identification, discarded recommendations, and torque

values.

737 AMM

25.3(g) A list of special tools needed. N/A

25.4 The instructions for Continued Airworthiness must

contain a section titled “Airworthiness Limitations” that

is segregated and clearly distinguishable from the rest of

the document.

05CAS469-D30

25.4(a)(1) The Airworthiness Limitations Section must set forth

each mandatory replacement time, structural inspection

procedure approved under section 25.571.

05CAS469-D30

25.4(b) If the instructions for Continued Airworthiness consist of

multiple documents, the Airworthiness Limitations

Section required by this paragraph must be included in

the principle manual.

05CAS469-D30

25.4(b)

For FAR Part

25 aircraft

The Airworthiness Limitation Section must contain a

legible statement in a prominent location that reads: “The

Airworthiness Limitations Section is FAA approved and

specifies inspections and other maintenance required

under sections 43.16 and 91.163 of the FAR’s unless an

alternative program has been FAA approved.”

05CAS469-D30

Documents

Cascade Aviation Services, Inc. · The Boeing 737 aircraft will have its eyebrow windows (cockpit windows #4 and 5) replaced by window blanks per Cascade Aviation Services Engineering