H26052 H26054 H26056
500  Window No. 4 Installation 
Feb 20/86  Figure 403A BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  56-11-31 Page 405 

Window No. 5 Installation  500 
56-11-31Page 406   Figure 403B BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  Feb 20/86 

500  Pattern for Typical Window Fastener Installation 
Feb 15/79  Figure 404  56-11-31 
Page 407 
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 

E.  Position window assembly (1) in window frame (10) and check that a uniform gap exists between outside edge of window and fuselage outer skin.
(1)  
Examine that aluminum spacers (2) are inserted in the bolt holes in the window assembly (1).

NOTE:  Retain the spacers by friction or other means until the retaining bolts and attaching nuts are installed. Do not bond the spacers. The spacers must be free to move on the bolts and within the bolt holes in the window.

(2)
Treat the bolt shanks with a corrosion preventive compound just prior to installation.

6.  Install Window No. 4 or No. 5 (Fig. 403A or 403B)
A.  Install window in frame.
CAUTION:  MAGNETIC OR HIGH PERMEABILITY MATERIALS SHALL NOT BE INSTALLED WITHIN A 20-INCH RADIUS FROM THE CENTER OF THE MAGNETIC COMPASS, NOR SHALL THEY BE INSTALLED NEARBY IF, AFTER MAINTENANCE REMOVAL, THEY MIGHT BE INSTALLED WITHIN THE 20-INCH RADIUS.
(1)  
Install retaining bolts (3). Install window No. 4 with non-magnetic fasteners within 20-inch radius of magnetic compass. Outside of 20-inch radius on window No. 4 alloy steel fasteners may be used. Install window No. 5 with alloy steel fasteners.

CAUTION:  USE ONLY NONMAGNETIC BOLTS (HEAT TREATED TO 140,000 PSI) ALONG TOP, BOTTOM, AND FORWARD EDGES BECAUSE OF PROXIMITY OF STANDBY COMPASS. BOLTS ATTACHING WINDOW RETAINING ANGLE AT AFT EDGE ARE NOT STANDARD AND MUST BE REPLACED ONLY BY IDENTICAL BOLT. OBSERVE SPECIFIED TORQUE FOR BOLTS ON EACH WINDOW INSTALLATION AS DAMAGE CAN RESULT IF TORQUE IS EXCEEDED.

(2)  
Install O-rings (4) and flat washers (5).

NOTE:  On thin window assemblies an additional nut washer (AN960-D416) (6), can be used to prevent engaging incomplete bolt threads.

(3)  
Install self-locking hex head nuts (7), finger-tight at this time.

(4)  
Torque each bolt 55 to 60 pound-inches on window No. 4 and 20 to 25 pound-inches on window No. 5, using a staggered sequence, diagonally back and forth across window in a criss-cross pattern. (See Fig. 404 for typical torque sequence.)

500 
56-11-31 Page 408  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  May 01/01 

CAUTION:  OBSERVE THE SPECIFIED TORQUE FOR BOLTS AS DAMAGE CAN RESULT IF THE TORQUE IS EXCEEDED.
NOTE:  Pressurized flight tends to bed any newly installed fixed window down in its frame. As a result, after initial pressurization if leakage occurs the attaching nuts should be checked. Any loose nut should be retightened to a torque of not more than 5 pound-inches above the run-on torque for the nut. Damage can result if this torque is exceeded. After this occasion no further retightening should ever be done unless water or air leaks occur, in which case, retightening of attaching nuts should again be limited to a torque of 5 pound-inches above the run-on torque for the nut.
B.  Apply masking tape over outside gap between window and skins to prevent contamination prior to filling with nylon cord and smoother.
C.  Remove strip of masking tape immediately over gap at outside edge of window. This can be done with a sharp knife or equivalent so as to leave strips of masking tape protecting the edges of the gap.
D.  Insert a clean dry nylon cord, slightly longer than window perimeter, in bottom of gap at outside edge of window. The two ends should meet in the upper aft corner of the window frame and overlap at approximately 0.5 inch.
NOTE:  To ease insertion of cord, stretch it slightly and tamp down into gap with a spatula if necessary.
E.  Inject aerodynamic smoother into the gap by means of a flow gun or with a spatula until the gap is completely filled (Fig. 405). Do not trap air under the smoother (Ref 56-11-0).
CAUTION:  SMOOTHER IS AVAILABLE WITH SEVERAL WORK LIVES TO SUIT A VARIETY OF JOBS. STEPS E., F., AND G. MUST BE COMPLETED DURING WORK LIFE SELECTED.
F.  Remove excess filler, while still wet, with a tool until just level with the masking tape.
　
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