Cascade Aviation Services, Inc.

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Cascade Aviation Services, Inc.Document Identification:Document No.INSTRUCTIONS FOR CONTINUED AIRWORTHINESS05CAS469-D30Project:Eyebrow Window Replacement, Boeing 737 Series AirplanesSTC red by:Edgar GraudinsDate: 8/25/05original revision signed byApproved by:Paul Kingswelloriginal revision signed byDate: 8/25/05

Cascade Aviation Services, Inc.REVISION PAGERevisionDescriptionDateApprovalNewOriginal Release.8/25/05See CoverPreparedAPage 2. Sec 7.0 Added hourly inspectionintervals.P. Kingswell9/8/05Checked:E. GraudinsBCover page: changed FAA project number toSTC number.Page 2: corrected W&B numbers in section 8.0.Page 3: added addition window blank partnumbers to Table 2.PreparedE. Graudins8/14/06Checked:B. NormanPreparedCRevised section 7.0 to clarify the inspectionintervals.E. Graudins10/19/06Checked:P. VallinsPreparedDRevised section 7.0 to incorporate inspectionintervals suggested by AEG.E. Graudins11/2/06Checked:P. VallinsPreparedEFPage 2: Clarified DET requirements. Updatedweight info in Table 1.Page 3: Updated part numbers in Table 2.Updated section 7.0 with new inspectioninterval definitions.Added new sections 8.0 and 9.0 for Part 26compliance.Instructions for Continued AirworthinessE. Graudins6/25/07Checked:P. VallinsPreparedE. Graudins4/27/09Checked:B. NormanDocument:Revision:F05CAS469-D30Page:II

Cascade Aviation Services, Inc.LIST OF ACTIVE PAGESSectionPageNumberRevisionLevelI (cover)IIIIIIVFFFF1234567NewFFFFFFAdded PagesPageRevision8FInstructions for Continued vision05CAS469-D30Page:III

Cascade Aviation Services, Inc.TABLE OF CONTENTSREVISION PAGE.IILIST OF ACTIVE PAGES . IIITABLE OF CONTENTS . IV1.0 SCOPE.12.0 PURPOSE.13.0 APPLICABILITY.14.0 ABBREVIATIONS.15.0 DESCRIPTION OF MODIFICATION .16.0 REFERENCES.17.0 INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE.28.0 FATIGUE AND DAMAGE TOLERANCE.29.0 ELECTRICAL WIRING INTERCONNECTION SYSTEM .210.0 WEIGHT AND BALANCE .311.0 MATERIALS AND TOOLS .312.0 AIRWORTHINESS LIMITATIONS.413.0 DOCUMENT CONTROL.414.0 FIGURES.515.0 CHECKLIST.6Instructions for Continued V

Cascade Aviation Services, Inc.1.0SCOPEThe scope of this document is to provide the necessary information for the maintenance andcontinued airworthiness of components installed on Boeing 737 series aircraft.2.0PURPOSEThe purpose of this document is to provide maintenance and continued airworthiness data inaccordance with CFR Part 25.1529 and Appendix H.3.0APPLICABILITYThis document is applicable to all models of 737 aircraft (737-100, -200, -200C, -300, -400, -500,-600, -700, -700C, -800, -900).4.0ABBREVIATIONSAEGFAACFRICA5.0Aircraft Evaluation GroupFederal Aviation AdministrationCode of Federal RegulationsInstructions for Continued AirworthinessDESCRIPTION OF MODIFICATIONA Supplemental Type Certificate approves this modification.The Boeing 737 aircraft will have its eyebrow windows (cockpit windows #4 and 5) replaced bywindow blanks per Cascade Aviation Services Engineering Drawing 05CAS469201 or05CAS469203.The existing eyebrow windows will be removed. New window blanks manufactured by CascadeAviation will be installed in their place. The surrounding airframe will not be affected, and theattachment of the window blanks will be identical to the OEM window installation. The windowheating circuit will be disabled. See Figure 1 for a typical window blank installation.6.0REFERENCESBoeing 737 Aircraft Maintenance Manual (AMM).Boeing 737 Structural Repair Manual (SRM).Instructions for Continued :1

Cascade Aviation Services, Inc.7.0INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULEOperator 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 canbe accomplished during the airline’s equivalent of a C-check). Removal or disassembly of thewindow blanks is not required for this inspection.Operator to perform a Detailed Inspection (DET) of the window blanks, support structure, andattaching hardware for damage or fatigue cracking within 30,000 flight cycles of the initialinstallation (this can be accomplished during the airline’s equivalent of a D-check, typically every24,000 flight cycles), and reinspected within every 30,000 cycles after that. In addition to normalinspection procedures, detailed inspection of the window blank also includes disassembly of thewindow 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). Windowblank may be left in place if cover and insulation can be removed without removal of windowblank from aircraft frame. All surfaces of the window blanks should be inspected visually, and asrequired, using a magnifying glass.If the inspection intervals noted above differ from those identified in AMM supplement05CAS469-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 arecovered by the Boeing Maintenance Manual and Structural Repair Manual. Cosmetic or structuraldamage to the window blanks may be repaired or the blanks replaced per Aircraft MaintenanceManual Supplement 05CAS469-D82.8.0FATIGUE AND DAMAGE TOLERANCEThe window frames that the window blanks interface with are considered Fatigue CriticalBaseline Structure (FCBS). Since the window blanks have the same interface loads as the OEMwindows, the existing Boeing inspection instructions and intervals for the surrounding airframeare 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 theblanks results in a low probability of failure from fatigue cracking. The window blanks should beinspected per section 7.0 above.9.0ELECTRICAL WIRING INTERCONNECTION SYSTEMThe eyebrow window blank replacement does not install any new wiring that would requireEWIS-ICA instructions. This modification does not affect the existing Boeing 737 EWIS-ICAdocument.Instructions for Continued AirworthinessDocument:Revision:F05CAS469-D30Page:2

Cascade Aviation Services, Inc.10.0WEIGHT AND BALANCEThe weight change to a 737 aircraft from the eyebrow window replacement is summarized in thefollowing table for all models of 737 aircraft. For detailed weight & balance data see report05CAS469-D20.Table 1: Weight change to 737 aircraftWeight Change (lbs)11.0Kit Number-2.205CAS469101-1 (or -3)-1.105CAS469101-1 (or -3)& 05CAS469102-1-2.205CAS469103-1NoteWindow blank installation (withintegral insulation and cover plate)Window blank installation withoptional insulation upgrade kitWindow blank installation (withseparate insulation and cover plate)MATERIALS AND TOOLSNo special materials or tools are required to maintain or inspect the window blanks.Table 2: The following parts can be repaired or replaced, as 10105CAS469508-101LH window #4 blank assyRH window #4 blank assyLH window #4 blank assyRH window #4 blank assyLH window #4 blank assyRH window #4 blank assyLH window #5 blank assyRH window #5 blank assyLH window #5 blank assyRH window #5 blank assyLH window #5 blank assyRH window #5 blank assyInsulated cover LH #4Insulated cover RH #4Insulated cover LH #5Insulated cover RH #5Nut plate assemblies*Bolt*GasketGasket* Parts identical to OEM window installation. Replacement parts are obtained from Boeing orany supplier of Boeing spares.Instructions for Continued AirworthinessDocument:Revision:F05CAS469-D30Page:3

Cascade Aviation Services, Inc.12.0AIRWORTHINESS LIMITATIONSThe Airworthiness Limitations section is FAA approved and specifies maintenance requiredunder Secs. 43.16 and 91.163 of the Federal Aviation Regulations unless an alternative programhas been FAA approved.There are no airworthiness limitations associated with this Supplemental Type Certificate.13.0DOCUMENT CONTROLCascade Aviation Services’ Document Control center will distribute supplements for all affectedaircraft manuals to end users. End users will be updated with the latest revision of allsupplements, as they are released. Updated manuals will be supplied by mail, email, website, orother means requested by the customer.Instructions for Continued AirworthinessDocument:Revision:F05CAS469-D30Page:4

Cascade Aviation Services, Inc.14.0FIGURESBoltSpacerNew Window BlankO-ring strip (part ofnut-plate assembly)Nut-plate assemblyNut-plate (part ofnut-plate assembly)FIGURE 1: Window #4 (LH) CAS InstallationInstructions for Continued AirworthinessDocument:Revision:F05CAS469-D30Page:5

Cascade Aviation Services, Inc.15.0CHECKLISTPart 25, Appendix H (b)(1)25.3(b)(1)CHECKLIST FOR 05CAS469-D30RequirementA program in manual that shows how changes to the ICAmade by the applicant will be distributedICAW in the form of a manual or manuals in a practicalarrangementA description of the aircraft and its installations,Its Engines and its systemsIts propellers and its systemsIts systems and installations, appliances and its systemsand installations.Reference Coverage05CAS469-D3005CAS469-D30737 AMMN/AN/AWindows 4 and 5 only:05CAS469401,05CAS469402,05CAS469201.Basic control and operating information describing how 737 AMMthe aircraft components and systems are controlled andhow the aircraft components and systems are operatedincluding any special limitations.Servicing information which cover details regarding N/Aservicing points, capacities of tanks, capacities ofreservoirs, types of fluids used, and pressures applicableto various systemsLocation of access panels for inspection and servicingN/AServicing information that covers details regarding N/Alocation and lubrication points, and the lubricant usedEquipment required for servicingN/ATow instructions and limitationsN/AMooring InformationN/AJacking InformationN/ALeveling InformationN/AScheduling information for each part of the aircraft that 05CAS469-D30provides the recommended periods, at which they shouldbe cleaned, inspected, adjusted, tested, lubricated, and thework recommended at these periods.Scheduling information for the aircraft’s engine that N/Aprovides the recommended period, at which they shouldbe cleaned, inspected, adjusted, tested, lubricated and thework recommended at these periods.Scheduling information for the aircraft’s Auxiliary Power N/AUnit (APU) that provides the recommended period atwhich they should be cleaned, inspected, adjusted, tested,Document: 05CAS469-D30Instructions for Continued AirworthinessRevision:FPage:6

Cascade Aviation Services, ementlubricated and the work recommended at these periods.Scheduling information for the aircraft’s propellers thatprovides the recommended period at which they shouldbe cleaned, inspected, adjusted, tested, lubricated and thework recommended at these periods.Scheduling information for the aircraft’s accessories thatprovides the recommended period at which they shouldbe cleaned, inspected, adjusted, tested, lubricated and thework recommended at these periods.Scheduling information for the aircraft’s instruments thatprovides the recommended period at which they shouldbe cleaned, inspected, adjusted, tested, lubricated and thework recommended at these periods.Scheduling information for the aircraft’s equipment thatprovides the recommended period, at which they shouldbe cleaned, inspected, adjusted, tested, lubricated and thework recommended at these periods.The degree of inspection for each part of the aircraft andits engines, auxiliary power unit, propellers, accessories,instruments and equipment.The applicable wear tolerancesThe applicant may refer to an accessory, instrument, orequipment manufacturer as the source of its informationif applicant shows that the item has an exceptionally highdegree of complexity requiring specialized maintenancetechniques, test equipment, or expertiseThe recommended overhaul periods and necessary crossreferences to the Airworthiness Limitation SectionAn inspection program that includes the frequency andextent of the inspection necessary to provide for theContinued Airworthiness of the aircraft.Troubleshooting information, describing problem,malfunctions, how to recognize those malfunctions andthe remedial action for those malfunctions.Information describing the order and method of removingand replacing engines with any necessary precautions tobe taken.Information describing the order and method of removingand replacing parts with any necessary precautions to betaken.Other general procedural instructions including storagelimitations and procedures for testing systems duringInstructions for Continued AirworthinessReference CoverageN/A05CAS469-D30N/AN/AACCESSORIES ONLY737 AMMN/AN/AN/A05CAS469-D30N/AN/A737 AMMN/ADocument:Revision:F05CAS469-D30Page:7

Cascade Aviation Services, Inc.RegulationRequirementground running, making symmetry checks, weighing anddetermining the center of gravity, lifting, and shoring.25.3(c)Diagrams of structural plates and information needed togain access for inspections when access plates are notprovided.25.3(d)Details for the application of special inspectiontechniques including radiographic and ultrasonic testingwhere such processes are specified.25.3(e)Information needed to apply protective treatment tostructure after inspection.25.3(f)All data relative to structural fasteners such asidentification, discarded recommendations, and torquevalues.25.3(g)A list of special tools needed.25.4The instructions for Continued Airworthiness mustcontain a section titled “Airworthiness Limitations” thatis segregated and clearly distinguishable from the rest ofthe document.25.4(a)(1)The Airworthiness Limitations Section must set fortheach mandatory replacement time, structural inspectionprocedure approved under section 25.571.25.4(b)If the instructions for Continued Airworthiness consist ofmultiple documents, the Airworthiness LimitationsSection required by this paragraph must be included inthe principle manual.25.4(b)The Airworthiness Limitation Section must contain aFor FAR Part legible statement in a prominent location that reads: “The25 aircraftAirworthiness Limitations Section is FAA approved andspecifies inspections and other maintenance requiredunder sections 43.16 and 91.163 of the FAR’s unless analternative program has been FAA approved.”Instructions for Continued AirworthinessReference CoverageN/AN/AN/A737 -D30Document:Revision:F05CAS469-D30Page:8

Boeing 737 Structural Repair Manual (SRM). Cascade Aviation Services, Inc. Instructions for Continued Airworthiness Document: 05CAS469-D30 Revision: Page: 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 .

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