October 28, 1999

Revision 1: May 15, 2003 747-35A2101

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 40

Commercial

Airplane

Group 747

Service Bulletin

Number: 747-35A2101

Date: October 28, 1999

Revision 1: May 15, 2003

ATA System: 3510

CAS

SUBJECT: OXYGEN - Crew Oxygen - Crew Oxygen System Low Pressure Flex Hose

Replacement

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 1999 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Unpublished Work - All Rights Reserved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, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, DC-8, DC-9,

DC-10, MD-10, MD-11, MD-80, MD-88, MD-90, and the red-white-and-blue Boeing livery are all trademarks

owned by The Boeing Company; and no trademark license is granted in connection with this document unless

provided in writing by Boeing.
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BOEING SERVICE BULLETIN 747-35A2101

BLANK PAGE
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Commercial

Airplane

Group 747

Service Bulletin

Number: 747-35A2101 Revision Transmittal Sheet

Date: October 28, 1999

Revision 1: May 15, 2003

ATA System: 3510

CAS

SUBJECT: OXYGEN - Crew Oxygen - Crew Oxygen System Low Pressure Flex Hose

Replacement

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes changed as shown in the initial release of this service bulletin.

If the protective tape was not applied to the hoses, apply the tape to all the new flight compartment hoses at the

next available opportunity.

REASON FOR REVISION

This revision is sent to advise affected operators of the following:

• The NOTE in the Background and Reason section was revised.

• The addition of the vendor equivalent, oxygen hose, part numbers and the addition of the tape, part

number in the Parts Necessary For Each Airplane section.

• The addition of a NOTE at the beginning of the Accomplishment Instructions to clarify which oxygen

hoses are to be replaced.

• The addition of instructions to remove and install the mask and demand regulator, along with the oxygen

boxes.

• The addition of a step in the Accomplishment Instructions to apply protective tape to the hoses.

• The addition of Figure 2 for the protective tape application.

• The data given in Information Notice 747-35A2101 IN 01 is included in this revision.

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 Release: October 28, 1999

Revision 1: Not Released
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BOEING SERVICE BULLETIN 747-35A2101

BLANK PAGE
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Commercial

Airplane

Group 747

Service Bulletin

Number: 747-35A2101 Summary

Date: October 28, 1999

Revision 1: May 15, 2003

ATA System: 3510

CAS

SUBJECT: OXYGEN - Crew Oxygen - Crew Oxygen System Low Pressure Flex Hose

Replacement

CONCURRENT REQUIREMENTS

None.

BACKGROUND

The changes provided in this service bulletin will help prevent damage to the low pressure oxygen flex hoses

that may be subjected to electrical current. An electrical grounding condition can cause the hose to melt or

burn.

One operator has reported damaged oxygen supply hoses on another Boeing model in August of 1997. This

damage has occurred due to a short circuit in the 757 Audio Select Panel. It sent an electrical current through

the support structure to the flight crew mask stowage box. This caused the spring inside the low pressure

oxygen hose to act as an electrical conductor and heat up. This caused the hose to burn through.

Also, a similar occurrence on a 737 was reported due to improper maintenance.

This service bulletin will replace low pressure oxygen hoses with non-conductive hoses located on the flight

deck. The replacement of the oxygen hoses will help prevent electrical current from passing through the

supporting spring which can cause the hose to melt or burn.

Boeing Service Related Problem (SRP) 747-SRP-35-0014 is related to this service bulletin.

Note: Operators affected by Boeing Service Bulletin 747-35A2088 should follow the flight deck hose routing

and clearance instructions provided by Service Bulletin 747-35A2088. All other operators should follow

the instructions in Service Bulletin 747-35A2101.

ACTION (PRR 85900-226)

Remove the crew oxygen boxes. Replace the existing low pressure hoses with new non-conductive hoses.

Install the crew oxygen boxes. Functional test the system.

EFFECTIVITY

All 747 airplanes line number 1 through 1229 as applicable.
October 28, 1999

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BOEING SERVICE BULLETIN 747-35A2101

COMPLIANCE

Boeing recommends compliance at the earliest opportunity when manpower, material and facilities are

available.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

MANPOWER

MATERIAL INFORMATION

None.

Airplanes Total Task Hours Elapsed Hours

747 Classics 2.5 2.5

747-400/D/F 1.75 1.75
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BOEING SERVICE BULLETIN 747-35A2101

(TYPICAL CONFIGURATION)

HOSES AS APPLICABLE

REPLACE OXYGEN BOX

HOSES AS APPLICABLE

REPLACE OXYGEN BOX

(TYPICAL CONFIGURATION)

747-400 FLIGHT COMPARTMENT

747 FLIGHT COMPARTMENT

S93303
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BOEING SERVICE BULLETIN 747-35A2101

BLANK PAGE
October 28, 1999

Revision 1: May 15, 2003 747-35A2101

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 9 of 40

Commercial

Airplane

Group 747

Service Bulletin

Number: 747-35A2101

Date: October 28, 1999

Revision 1: May 15, 2003

ATA System: 3510

CAS

SUBJECT: OXYGEN - Crew Oxygen - Crew Oxygen System Low Pressure Flex Hose

Replacement

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-30300 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 85900-226 for data about this change.

Airplane models:

747-100 747-100B 747-100B SUD 747-200B

747-200C 747-200F 747-300 747-400

747-400D 747-400F 747SP 747SR

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

AAR AIRCRAFT SALES AND LEASING (AFD)

1 RA313 RA315 RB681–RB682 RD134

AERO CONTROLS (AEO)

1 RA722–RA723

AEROLINEAS ARGENTINAS (ARG)

1 RD053 RD122–RD127

AGES AIRCRAFT SALES & LEASING (AGJ)

1 RB004

AIR ATLANTA ICELANDIC (AID)

1 RA526 RA534 RB411–RB413 RD141

RD143 RD352–RD355 RD414 RD472–RD473

RD647–RD648 RD771 RS332–RS333
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BOEING SERVICE BULLETIN 747-35A2101

AIR CANADA (ACN)

1 RA750 RD531 RT101–RT103 RT701–RT702

RU059

AIR CHINA (BEJ)

1 RD781–RD783 RM811–RM813 RR451 RT031–RT035

RT878–RT880

AIR FRANCE (AFA)

1 RA253 RD271–RD272 RD651–RD655 RD657–RD659

RD721–RD722 RD791–RD792 RR302 RR304

RR306–RR309 RR332 RS751–RS752 RT071–RT075

RT121 RT591 RT711–RT716

AIR GABON (GBN)

1 RD661

AIR INDIA (AIN)

1 RA728–RA731 RS781–RS782 RU001–RU006

AIR MADAGASCAR (MAD)

1 RD561

AIR NAMIBIA (NAM)

1 RT137

AIR NEW ZEALAND (ANZ)

1 RM082 RM191–RM192 RT671–RT673 RT703

RT932

AIR PACIFIC (APC)

1 RD518

AIR PULLMANTUR (PUL)

1 RS331

AIRFREIGHT EXPRESS LIMITED (AIF)

1 RD442 RR221

ALBARAKA (AAB)

1 RB102

ALITALIA (ALI)

1 RD751 RR561

ALL NIPPON AIRWAYS (ANA)

1 RB689–RB695 RB697 RD231–RD232 RM231–RM232

RT751–RT757 RT776–RT777 RU831–RU841

AMIRI FLIGHT (ABD)

1 RH102 RM084
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BOEING SERVICE BULLETIN 747-35A2101

ASIANA AIRLINES (AAR)

1 RM071 RM861 RR746–RR748 RT131–RT136

RU032

ATLAS AIR (TLS)

1 RB683–RB685 RD044 RD361–RD366 RD411–RD412

RD641–RD643 RD646 RD691–RD692 RD752–RD755

RJ333 RM892–RM899 RR301 RR303

RS721–RS722 RS762

AVIATION EXPOSURE MANAGEMENT (EXU)

1 RD131–RD132

AVIATION PARTNERS L.L.C. (APM)

1 RS241

BAHRAIN ROYAL FLIGHT (BHR)

1 RG009

BOEING (TBC)

1 RB688 RR222–RR223

BOEING AIRCRAFT HOLDING CO. (BHC)

1 RD181 RD451–RD456

BOEING CAPITAL CORPORATION (ZMF)

1 RB687 RD072 RJ132 RR201

BRITISH AIRWAYS (BAB)

1 RD139 RD311 RM096–RM097 RM136–RM145

RM261–RM264 RT471–RT499 RU121–RU132

C.A.L. CARGO AIR LINES (CRG)

1 RJ331–RJ332

C.I.T. LEASING CORPORATION (TCI)

1 RD047

CAMEROON AIRLINES (CAM)

1 RS238

CARGOLUX AIRLINES (CLX)

1 RM881–RM883 RR701 RR721–RR724

CATHAY PACIFIC AIRWAYS (CAT)

1 RD358 RD581–RD583 RR441–RR442 RR531

RR951–RR952 RT451–RT469

CHINA AIRLINES (CHI)

1 RD551 RM021–RM024 RR521–RR522 RT631–RT634

RT636–RT640
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BOEING SERVICE BULLETIN 747-35A2101

CONTINENTAL AIRLINES (CAL)

1 RA561 RB005–RB006

CORSAIR (COR)

1 RA023 RA675 RG124 RS233

RS235 RS237 RS239–RS240

DRAGONAIR (DRG)

1 RS741 RS743 RS771

DUBAI AIR WING (DAW)

1 RD622 RG191 RG193

EGYPTAIR (EGP)

1 RS731–RS732

EL AL ISRAEL AIRLINES (ELA)

1 RA784 RB007 RJ152 RM091

RR225–RR226 RU081–RU083

EUROPEAN AVIATION AIR CHARTER (EUL)

1 RD135–RD138 RD140

EVA AIR (EVA)

1 RM116–RM117 RT161–RT168 RT951–RT955

EVERGREEN INTERNATIONAL A/L (EVR)

1 RA004 RA028 RA631 RA633

RB604 RB607 RD041–RD043 RJ131

RJ133

FINOVA (GRB)

1 RA015 RA651 RS761

FLEET CAPITAL LEASING (SBC)

1 RA106 RD001–RD002

FLIGHTPLAN INTERNATIONAL (FLP)

1 RA003

GARUDA INDONESIA (GIA)

1 RD421–RD424 RT931 RU061–RU062

GE (GEC)

1 RA016

GE CAPITAL CORPORATION (GEF)

1 RA005 RA007 RA013 RA027

RA634
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BOEING SERVICE BULLETIN 747-35A2101

GENERIC EMBARGOED CUSTOMER (YWV)

1 RA101–RA103 RA112 RA161–RA163 RA303

RA535 RA537 RG095 RG171–RG172

RJ301–RJ303 RR001–RR004

GLOBAL AIR LEASING (GAO)

1 RG164

GLOBAL PEACE INITIATIVE (GPI)

1 RG174

GLOBAL SUPPLY SYSTEMS (GSS)

1 RM891

GOVERNMENT OF JAPAN (JAG)

1 RT681–RT682

HM THE SULTAN'S FLIGHT (BWN)

1 RT440

HYDRO AIR (HYR)

1 RJ151

IBERIA AIRLINES (IBE)

1 RA585 RD431–RD435

IRAN AIR (IRN)

1 RB711 RD681–RD682 RG101–RG104

JAPAN AIRLINES (JAL)

1 RA528 RA543–RA548 RB723 RD055

RD221–RD227 RM126–RM129 RM316 RR262

RR264–RR267 RR361–RR362 RS001–RS002 RS251–RS259

RS265–RS268 RT641–RT657 RT861–RT864 RT966–RT967

RU801–RU809

JAPAN ASIA AIRWAYS (JAA)

1 RS263

JUMBO JET LEASING (JJL)

1 RA217 RA532–RA533 RA539 RA541

K.B.A. FOUNDATION (KBA)

1 RT877

KABO AIR (KAB)

1 RA305–RA306 RA316 RA501–RA502 RA560

RB008–RB009 RD121

KALITTA AIR (KAC)

1 RA402 RA524 RA635 RA749

RD082–RD083 RD201 RD621 RD623

RR261
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BOEING SERVICE BULLETIN 747-35A2101

KALITTA LEASING (KAA)

1 RB721

KHALIFA AIRWAYS (KHL)

1 RT876

KLM - ROYAL DUTCH AIRLINES (KLM)

1 RD381–RD383 RD601–RD607 RM801 RS711–RS713

RT001–RT014 RT531–RT535

KOREAN AIR (KAL)

1 RM011–RM012 RM871 RR022–RR025 RR861–RR862

RS292 RS786 RT061 RT571–RT588

RT590 RT811–RT814

KUWAIT AIRWAYS (KUW)

1 RD202 RD204 RT151

LOGISTIC AIR, INC. (LGA)

1 RB722

LUFTHANSA GERMAN AIRLINES (DLH)

1 RD291–RD292 RD649 RD772–RD775 RM001–RM002

RR202–RR206 RT041–RT047 RT431–RT439 RT441–RT447

MALAYSIA AIRLINES (MAS)

1 RD142 RD144 RM036–RM038 RT021–RT022

RT743–RT750 RU016–RU017

MARTINAIR HOLLAND (MTH)

1 RJ321–RJ322 RR310

MK AIRLINES (MKA)

1 RD441 RD741 RR224 RR336

RR421

NASA (NAS)

1 RA908 RB601

NIPPON CARGO AIRLINES (NCA)

1 RB696 RD233–RD235 RD461 RR551–RR556

NORTHWEST AIRLINES (NWA)

1 RA370–RA373 RD056–RD057 RD241–RD243 RD251–RD262

RD301–RD302 RM241–RM243 RR005 RR341–RR345

RR431–RR432 RR503 RR566 RS701–RS702

RT401–RT410

OMAN ROYAL FLIGHT (RFO)

1 RG161 RG163

ORIENT THAI AIRLINES (OTH)

1 RA527 RA540
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BOEING SERVICE BULLETIN 747-35A2101

PAKISTAN INT'L AIRLINES (PIA)

1 RD003–RD004 RD101–RD104 RD701–RD702 RS301–RS306

PANAIR (PNR)

1 RG122

PEGASUS AVIATION, INC. (PSS)

1 RB010 RD513

PHILIPPINE AIRLINES (PAL)

1 RD171–RD172 RD413 RT152 RU051–RU052

RU060

POLAR AIR CARGO (PAO)

1 RA726 RA910 RA914 RD425–RD426

RD592 RR501 RR504

PRATT & WHITNEY ENGINE SERVICE (PWE)

1 RG212–RG213

QANTAS (QAN)

1 RD519 RS271–RS276 RT551–RT568 RT741–RT742

RU031

ROYAL AIR MAROC (RAM)

1 RD671 RT717

SAUDI ARABIAN AIRLINES (SVA)

1 RB741–RB746 RB748 RH121 RM156–RM157

RR526 RS311–RS320 RU101–RU102

SAUDI ROYAL FLIGHT (SRF)

1 RH101 RH122 RS699

SECURITY CUSTOMER (UO1)

1 RB013–RB016 RD166–RD167

SINGAPORE AIRLINES (SIA)

1 RM851–RM852 RR851–RR856 RT501–RT530 RT831–RT835

RT837

SOUTH AFRICAN AIRWAYS (SAA)

1 RB071–RB075 RG121 RG123 RG125

RM081 RM083 RM146–RM147 RS211–RS212

RS221–RS222 RS232 RS236 RT781–RT784

SOUTHERN AIR (SOF)

1 RD182 RR305

SYRIANAIR (SYR)

1 RG141–RG142
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BOEING SERVICE BULLETIN 747-35A2101

TAAG (ANGOLA AIRLINES) (ANG)

1 RS703 RS742

TAG AVIATION (TAG)

1 RG173

THAI AIRWAYS INTERNATIONAL (TII)

1 RM026–RM027 RS341–RS342 RT691–RT699 RT801–RT803

TRANSJET AIRWAYS (TSX)

1 RB001 RD045–RD046

UNITED AIRLINES (UAL)

1 RA903 RA906–RA907 RB011 RD516

RG091 RM166–RM176 RT411–RT412 RT601–RT630

UNITED TECHNOLOGIES P & W (UTC)

1 RG211

UPS (UPS)

1 RA026 RA029 RA033 RA901–RA902

RA911–RA913 RA915–RA916 RB421 RB605

RD051–RD052 RD054 RD058–RD059 RD571

RD593

UT FINANCE CORPORATION (ZZJ)

1 RA542

VIRGIN ATLANTIC AIRWAYS (VAA)

1 RD356–RD357 RD471 RD474–RD475 RM051

RT945–RT949

WINGS WORLD WIDE (WWW)

1 RG221–RG222

WORLDWIDE AIRCRAFT HOLDING CO. (WAH)

1 RG008

YEMENIA (YEM)

1 RG162

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

RA001–RA034 1

RA101–RA115 1

RA161–RA164 1

RA201–RA203 1

RA216–RA217 1

RA245–RA246 1
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BOEING SERVICE BULLETIN 747-35A2101

RA251–RA266 1

RA301–RA318 1

RA351–RA360 1

RA369–RA373 1

RA401–RA418 1

RA501–RA502 1

RA521–RA528 1

RA532–RA548 1

RA551–RA552 1

RA559–RA561 1

RA581–RA582 1

RA585 1

RA601–RA602 1

RA631–RA635 1

RA651–RA652 1

RA671–RA677 1

RA701–RA702 1

RA721–RA731 1

RA741–RA745 1

RA749–RA750 1

RA761–RA762 1

RA781–RA784 1

RA901–RA916 1

RB001–RB016 1

RB041–RB044 1

RB071–RB075 1

RB101–RB102 1

RB411–RB413 1

RB421 1

RB601–RB607 1

RB681–RB697 1

RB711 1

RB721–RB723 1

RB741–RB748 1

RD001–RD004 1

RD021–RD022 1

RD041–RD059 1

RD071–RD072 1

RD081–RD083 1

Variable Group
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BOEING SERVICE BULLETIN 747-35A2101

RD091–RD092 1

RD101–RD104 1

RD121–RD127 1

RD131–RD144 1

RD166–RD167 1

RD171–RD172 1

RD181–RD183 1

RD201–RD204 1

RD221–RD227 1

RD231–RD235 1

RD241–RD243 1

RD251–RD262 1

RD271–RD272 1

RD291–RD292 1

RD301–RD302 1

RD311 1

RD351–RD358 1

RD361–RD366 1

RD381–RD383 1

RD411–RD414 1

RD421–RD426 1

RD431–RD435 1

RD441–RD442 1

RD451–RD456 1

RD461 1

RD471–RD475 1

RD513–RD519 1

RD531–RD533 1

RD551 1

RD561 1

RD571 1

RD581–RD583 1

RD591–RD593 1

RD601–RD607 1

RD621–RD623 1

RD641–RD649 1

RD651–RD659 1

RD661 1

RD671 1

Variable Group
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BOEING SERVICE BULLETIN 747-35A2101

RD681–RD682 1

RD691–RD692 1

RD701–RD702 1

RD721–RD722 1

RD741–RD742 1

RD751–RD755 1

RD761 1

RD771–RD775 1

RD781–RD783 1

RD791–RD792 1

RE001 1

RG001–RG009 1

RG091 1

RG095 1

RG101–RG104 1

RG121–RG126 1

RG141–RG142 1

RG161–RG164 1

RG171–RG174 1

RG191–RG193 1

RG211–RG213 1

RG221–RG222 1

RH101–RH102 1

RH111–RH112 1

RH121–RH122 1

RJ131–RJ133 1

RJ151–RJ152 1

RJ301–RJ303 1

RJ321–RJ322 1

RJ331–RJ333 1

RM001–RM002 1

RM011–RM012 1

RM021–RM024 1

RM026–RM027 1

RM036–RM038 1

RM051 1

RM071 1

RM081–RM084 1

RM091 1

Variable Group
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BOEING SERVICE BULLETIN 747-35A2101

RM096–RM097 1

RM116–RM117 1

RM126–RM129 1

RM136–RM147 1

RM156–RM157 1

RM166–RM176 1

RM191–RM192 1

RM231–RM232 1

RM241–RM243 1

RM261–RM264 1

RM316 1

RM801 1

RM811–RM813 1

RM851–RM852 1

RM861 1

RM871 1

RM881–RM883 1

RM891–RM899 1

RR001–RR005 1

RR021–RR025 1

RR031 1

RR201–RR206 1

RR221–RR226 1

RR261–RR267 1

RR301–RR310 1

RR331–RR332 1

RR336 1

RR341–RR345 1

RR361–RR362 1

RR421–RR422 1

RR431–RR432 1

RR441–RR442 1

RR451 1

RR501–RR504 1

RR521–RR522 1

RR526 1

RR531 1

RR551–RR556 1

RR561 1

Variable Group
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BOEING SERVICE BULLETIN 747-35A2101

RR566 1

RR701 1

RR721–RR724 1

RR746–RR748 1

RR851–RR856 1

RR861–RR862 1

RR951–RR952 1

RS001–RS002 1

RS201 1

RS211–RS212 1

RS221–RS222 1

RS231–RS241 1

RS251–RS259 1

RS263 1

RS265–RS268 1

RS271–RS276 1

RS291–RS292 1

RS301–RS306 1

RS311–RS320 1

RS331–RS333 1

RS341–RS342 1

RS699 1

RS701–RS703 1

RS711–RS713 1

RS721–RS722 1

RS731–RS732 1

RS741–RS743 1

RS751–RS752 1

RS761–RS762 1

RS771 1

RS781–RS782 1

RS786 1

RT001–RT014 1

RT021–RT022 1

RT031–RT035 1

RT041–RT047 1

RT061 1

RT071–RT075 1

RT101–RT103 1

Variable Group
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BOEING SERVICE BULLETIN 747-35A2101

RT121 1

RT131–RT137 1

RT151–RT152 1

RT161–RT168 1

RT401–RT412 1

RT431–RT447 1

RT451–RT469 1

RT471–RT499 1

RT501–RT535 1

RT551–RT568 1

RT571–RT591 1

RT601–RT657 1

RT671–RT673 1

RT681–RT682 1

RT691–RT699 1

RT701–RT704 1

RT711–RT717 1

RT741–RT757 1

RT776–RT777 1

RT781–RT784 1

RT801–RT803 1

RT811–RT814 1

RT831–RT837 1

RT861–RT864 1

RT876–RT880 1

RT931–RT932 1

RT945–RT949 1

RT951–RT955 1

RT966–RT967 1

RU001–RU006 1

RU016–RU017 1

RU031–RU032 1

RU051–RU052 1

RU059–RU062 1

RU081–RU083 1

RU101–RU102 1

RU121–RU132 1

RU801–RU809 1

RU831–RU841 1

Variable Group
October 28, 1999

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BOEING SERVICE BULLETIN 747-35A2101

2. Spares Affected

None.

B. Concurrent Requirements

None.

C. Reason

The changes provided in this service bulletin will help prevent damage to the low pressure oxygen

flex hoses that may be subjected to electrical current. An electrical grounding condition can cause

the hose to melt or burn.

One operator has reported damaged oxygen supply lines on another Boeing model in August of

1997. This damage has occurred due to a short circuit in the 757 Audio Select Panel. It sent an

electrical current through the support structure to the flight crew mask stowage box. This caused the

spring inside the low pressure oxygen hose to act as an electrical conductor and heat up. This

caused the hose to burn through.

Also, a similar occurrence on a 737 was reported due to improper maintenance.

This service bulletin will replace low pressure oxygen hoses with non-conductive hoses located on

the flight deck. The replacement of the oxygen hoses will help prevent electrical current from

passing through the supporting spring which can cause the hose to melt or burn.

Revision 1 is sent to advise affected operators of the following:

• The NOTE in the Background and Reason section was revised.

• The addition of the vendor equivalent oxygen hose part numbers and the addition of the tape

part number in the Parts Necessary For Each Airplane section.

• The addition of a NOTE at the beginning of the Accomplishment Instructions to clarify which

oxygen hoses are to be replaced.

• The addition of instructions to remove and install the mask and demand regulator along with the

oxygen boxes

• The addition of a step in the Accomplishment Instructions to apply protective tape to the hoses.

• The addition of Figure 2 for the protective tape application.

• The data given in Information Notice 747-35A2101 IN 01 is included in this revision.

Boeing Service Related Problem (SRP) 747-SRP-35-0014 is related to this service bulletin.

Note: Operators affected by Boeing Service Bulletin 747-35A2088 should follow the flight deck hose

routing and clearance instructions provided by Service Bulletin 747-35A2088. All other

operators should follow the instructions in Service Bulletin 747-35A2101.

D. Description

Remove the crew oxygen boxes. Replace the existing low pressure hoses with new non-conductive

hoses. Install the crew oxygen boxes. Functional test the system.

Revision 1 - More work is necessary on airplanes changed as shown in the initial release of this

service bulletin.
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If the protective tape was not applied to the hoses, apply the tape to all the new flight compartment

hoses at the next available opportunity.

An evaluation form is attached to this service bulletin. Please use this form to tell us what you think

of the quality of this service bulletin.

E. Compliance

Boeing recommends compliance at the earliest opportunity when manpower, material and facilities

are available.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes

specified in this service bulletin comply with the applicable Federal Aviation Regulations (FAR) and

are FAA approved. This service bulletin and the FAA approval were based on the airplane in its

original Boeing delivery configuration or as modified by other FAA 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.

G. Manpower

The table below shows an estimate of the man-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

man-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.

For 747 Classic Airplanes:

For 747-400/D/F Airplanes:

Task Number of Persons Man-Hours Elapsed Time (Hours)

Access 1 .75 .75

Replace hoses 1 1.0 1.0

Restore 1 .75 .75

TOTAL FOR EACH AIRPLANE 2.5 2.5

Task Number of Persons Man-Hours Elapsed Time (Hours)

Access 1 .50 .50

Replace hoses 1 .75 .75

Restore 1 .50 .50

TOTAL FOR EACH AIRPLANE 1.75 1.75
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H. Weight and Balance Changes

None.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 85900-226

b. Service Related Problem (SRP) 747-SRP-35-0014

c. 747 Maintenance Manual (AMM) Subject 35-00-00, 35-11-00, 35-11-07, 35-11-18

d. Boeing Service Bulletin 747-35A2088, “OXYGEN - Crew Oxygen Systems - Prevent

Chafing of Oxygen Box Flexible Hose and Microphone Wire”

2. Data supplied with this Service Bulletin:

None.

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

232U7409 Oxygen Installation - Navigator, Modification

232U8002 Equipment Installation - Crew Oxygen

65B40025 Tubing Instl - Crew Oxygen

65B45015 Tubing Instl - Crew Oxygen (MOD)

Publication Chapter-Section

747 Illustrated Parts Catalog 35-11
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BOEING SERVICE BULLETIN 747-35A2101

2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary For Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service

bulletin does not show the Boeing price and supply data.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service

bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

None.
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2. Parts and Materials Supplied by the Operator:

3. Parts Modified and Reidentified:

See Appendix A - Existing Accountability Table.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

See the table in section 2.C.2. Parts and Materials Supplied by the Operator for the Hose Assembly

part numbers.

E. Special Tooling - Price and Availability

None.

QTY Boeing Part Number / Vendor Part Number Name

(a) 60B50059-601 / 38001-601 (b) Hose Assy

(a) 60B50059-602 / 38001-602 (b) Hose Assy

(a) 60B50059-603 / 38001-603 (b) Hose Assy

(a) 60B50059-604 / 38001-604 (b) Hose Assy

(a) 60B50059-605 / 38001-605 (b) Hose Assy

(a) 60B50059-606 / 38001-606 (b) Hose Assy

(a) 60B50059-607 / 38001-607 (b) Hose Assy

(a) 60B50059-608 / 38001-608 (b) Hose Assy

(a) 60B50059-609 / 38001-609 (b) Hose Assy

(a) 60B50059-610 / 38001-610 (b) Hose Assy

(a) 60B50059-612 / 38001-612 (b) Hose Assy

1 Roll 232U8002-16 (c) (d) (e) Protective Tape

(a) For Hose quantity requirements, see Illustrated Parts Catalog 35-11 for customer specific configuration.

(b) HydraFlow (V24984)

13529 East 166th Street

Cerritos, CA 90703-2203 (USA)

(c) Permacel P29 or Scotch 3M, No. 474 protective tape is 3/4 inches wide X 36 yards

long.

(d) Permacel Division, Johnson & Johnson (V99742)

U.S. Highway 101, P.O. Box 671

New Brunswick, NJ 08903 (USA)

(e) Minnesota Mining and Manufacturing Company (V26066)

3M Center

St. Paul, MN 55144-1000 (USA)
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F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But,

maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be

necessary. Examine operator tool supply to make sure all necessary tools are available.
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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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 instructions for this service bulletin are only for the replacement of the oxygen hoses

located at the captain, first officer, flight engineer, and the observers positions. The

replacement applies only to the positions with oxygen mask stowage boxes or panel

mounted regulators, and not the standard type passenger masks.

4. Due to the multiple configurations of the 747 Classic and the 747-400, the only Figure

that will be shown is the Oxygen Box Hose Typical Locations.

B. WORK INSTRUCTIONS

CAUTION: OXYGEN SYSTEM COMPONENTS REQUIRE SPECIAL CARE AND HANDLING

PROCEDURES. REVIEW THE SAFETY AND MAINTENANCE PROCESSES

SHOWN IN THE 747 CLASSIC AND THE 747-400 AMM 35-00-00, PRIOR TO

MAKING ANY CHANGES TO THE OXYGEN SYSTEM.

1. Remove the oxygen masks and oxygen stowage boxes or the panel mounted regulators, as

shown in the 747 Classic AMM 35-11-07 and 35-11-18 or the 747-400 AMM 35-00-00 and 35-

11-18, or operator's equivalent procedures.

2. Remove the existing low pressure, flex oxygen hoses as shown in the 747 Classic AMM 35-00-

00 or the 747-400 AMM 35-11-18, or operator's equivalent procedure.

Note:

1. Make sure that the hose assembly elbows and unions do not move during hose

replacement. Orientation of the elbows and unions are essential in maintaining

proper clearances with other structure.

2. Before dicarding the existing low pressure oxygen flex hose, record the part number.

See Appendix A - Existing Parts Accountability Table for applicable new low

pressure flex hose.

3. If the low pressure oxygen hoses have already been installed as shown in this

service bulletin, and application of the tape was not added, apply the tape to the

hose at the next available opportunity.

3. Apply protective tape to all of the crew low pressure, oxygen hoses as shown in Figure 2.

4. Install the applicable new, low pressure, flex oxygen hoses as shown in the 747 Classic AMM

35-00-00 or the 747-400 AMM 35-00-00 and 35-11-18, or operator's equivalent procedure.
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Note: Make sure that there is a positive separation between the oxygen hoses, structure,

electrical wiring and equipment as shown in 747 Classic and 747-400 AMM 35-00-00 or

operators equivalent procedures.

5. Install the oxygen stowage boxes and oxygen masks or the panel mounted regulators, as

shown in the 747 Classic AMM 35-11-07 and 35-11-18 or the 747-400 AMM 35-11-18, or

operator's equivalent procedures.

6. Functional test the crew oxygen system as shown in the 747 Classic AMM 35-11-00, "Crew

Oxygen System Operational Test" and "System Leakage Test" or the 747-400 AMM 35-11-00,

"Crew Oxygen Operational Test" and "Crew Oxygen Leak Test," or operator's equivalent

procedure.

7. Put the airplane back to a serviceable condition.
FIGURE 1: OXYGEN BOX HOSE TYPICAL LOCATIONS

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BOEING SERVICE BULLETIN 747-35A2101

FIGURE 1: OXYGEN BOX HOSE TYPICAL LOCATIONS

(TYPICAL CONFIGURATION)

HOSES AS APPLICABLE

REPLACE OXYGEN BOX

HOSES AS APPLICABLE

REPLACE OXYGEN BOX

(TYPICAL CONFIGURATION)

747-400 FLIGHT COMPARTMENT

747 FLIGHT COMPARTMENT

S96677

(SHEET 1 OF 1)
FIGURE 2: TAPE APPLICATION

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BOEING SERVICE BULLETIN 747-35A2101

FIGURE 2: TAPE APPLICATION

The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

STEP TASK NAME PART NUMBER QTY NOTES

1 Apply Protective Tape 232U8002-16 1

Roll

2 layers of Permacel P29 or

Scotch 3M (No. 474) protective

tape over entire length of hose.

60 DEGREES

1

V27438

OXYGEN HOSE

0.0625

OVERLAP

(SHEET 1 OF 1)
APPENDIX A: EXISTING PARTS ACCOUNTABILITY TABLE

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BOEING SERVICE BULLETIN 747-35A2101

APPENDIX A: EXISTING PARTS ACCOUNTABILITY TABLE

Existing Part Number RUC Name QTY New Part Number PNC RC

60B50059-19 DIS Hose Assy (a) 60B50059-601 S A

60B50059-20 DIS Hose Assy (a) 60B50059-602 S A

60B50059-60 DIS Hose Assy (a) 60B50059-603 S A

60B50059-62 DIS Hose Assy (a) 60B50059-604 S A

60B50059-69 DIS Hose Assy (a) 60B50059-605 S A

60B50059-70 DIS Hose Assy (a) 60B50059-606 S A

60B50059-81 DIS Hose Assy (a) 60B50059-607 S A

60B50059-94 DIS Hose Assy (a) 60B50059-608 S A

60B50059-95 DIS Hose Assy (a) 60B50059-609 S A

60B50059-101 DIS Hose Assy (a) 60B50059-610 S A

60B50059-129 DIS Hose Assy (a) 60B50059-612 S A

(a) For Hose quantity requirements, see Illustrated Parts Catalog 35-11 for customer specific configuration.

RUC Recommended Use Code

DIS - Discard the part.

PNC Part Number Code

S - To get a new part, use this part number in your order.

- This is the part number after the change given in this service bulletin.

- This part is used in production.

RC Replacement Code

A - Do not use the existing part to replace the new or changed part.
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Table of Contents

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Table of Contents

Revision Transmittal Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 25

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 25

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 25

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 28

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 29

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

A. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

FIGURE 1: OXYGEN BOX HOSE TYPICAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 2: TAPE APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

APPENDIX A: EXISTING PARTS ACCOUNTABILITY TABLE . . . . . . . . . . . . . . . . . . . . . . 35
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Commercial

Airplane

Group 747

Service Bulletin

Number: 747-35A2101 Evaluation Form

Date: October 28, 1999

Revision 1: May 15, 2003

ATA System: 3510

CAS

SUBJECT: OXYGEN - Crew Oxygen - Crew Oxygen System Low Pressure Flex Hose

Replacement

Use this evaluation form to tell us what you think of the quality of this service bulletin. We will use the data that

you give us to improve the quality of our service bulletins.

Note: Please do not use this evaluation form to tell us to make changes to your manuals. To make these

changes, please use a Publication Change Request (PCR) form.

Please give us this data:

(If necessary, please use the other side. Thank you for the time you used to give us your comments.)

OPERATOR: ______________________________________ TODAY’S DATE:_______________________

PREPARED BY: ___________________________________ TITLE: ______________________________

ORGANIZATION: __________________________________ TELEX CODE: ________________________

TELEPHONE NUMBER: _____________________________ BASE: ______________________________

Please rate the quality of this service bulletin: (good) 4 3 2 1 (poor)

Please rate the quality of the illustrations: (good) 4 3 2 1 (poor)

Will you do the change given by this service bulletin? Yes___ No___ If not, please explain:

Is this service bulletin easy to understand? Yes___ No___ If not, please explain:

Is this service bulletin easy to use? Yes___ No___ If not, please explain:

Are the Planning Information, Material Information, and

Accomplishment Instructions accurate? Yes___ No___ If not, please explain:

Is the Manpower estimate accurate? Yes___ No___ If not, please explain:

Give the completed evaluation form to your Boeing Field Service Representative or send the evaluation form

directly to this address:

Manager, Service Bulletin Engineering

Boeing Commercial Airplanes Group

P.O. Box 3707, Mail Code 2H-36

Seattle, WA 98124-2207 USA
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BOEING SERVICE BULLETIN 747-35A2101