### Commercial **Airplanes** 

# 707 Service Bulletin **ALERT Number: A3538**  Original Issue: October 02, 2013 ATA System: 3511 3512 **SUBJECT:** OXYGEN - Flight Crew Oxygen System - Low Pressure Oxygen Flex Hose Replacement Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws. 9E991 ECCN: 

## BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2013 Boeing. Unpublished Work. All Rights Reserved. Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company. Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries 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.

Original Issue: October 02, 2013 A3538 1 of 28 2.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 2 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**

BLANK PAGE**Table of Contents** Summary...................................................... 5 1. PLANNING INFORMATION ........................................ 9 A. Effectivity................................................ 9 1. Airplanes............................................. 9 2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B. Concurrent Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H. Weight and Balance Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 I. Electrical Load Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Data Supplied with this Service Bulletin:. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3. Installation Drawings Used in the Preparation of this Service Bulletin:. . . . . . . . . . . 15 K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 L. Interchangeability and Intermixability of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . 16 M. Software Accomplishment Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. MATERIAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 C. Parts Necessary for Each Airplane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2. Parts and Materials Supplied by the Operator. . . . . . . . . . . . . . . . . . . . . . . . 17 3. Parts Modified and Reidentified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4. Parts Removed and Not Replaced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 D. Parts Necessary to Change Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F. Special Tooling Necessary to do this Service Bulletin. . . . . . . . . . . . . . . . . . . . . . . 18 3. ACCOMPLISHMENT INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 B. WORK INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 FIGURE 1: FLIGHT COMPARTMENT - CAPTAINS OXYGEN HOSE ASSEMBLY - REPLACEMENT . 21 FIGURE 2: FLIGHT COMPARTMENT - FIRST OFFICERS OXYGEN HOSE ASSEMBLY - REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FIGURE 3: FLIGHT COMPARTMENT - OBSERVERS OXYGEN HOSE ASSEMBLY - REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 FIGURE 4: FLIGHT COMPARTMENT - NAVIGATORS OXYGEN HOSE ASSEMBLY - REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 3 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 4 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# 707 Service Bulletin **ALERT Summary**  **Number: A3538** Original Issue: October 02, 2013 ATA System: 3511 3512 **SUBJECT:** OXYGEN - Flight Crew Oxygen System - Low Pressure Oxygen Flex Hose Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **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. If the changes in this service bulletin are not done, an electrical grounding condition can result, causing the hose to melt or burn and release smoke and/or fire into the flight compartment. This service bulletin will replace low pressure oxygen flex hoses with non-conductive low pressure oxygen flex hoses located in the flight compartment. Boeing Service Related Problem (SRP) 707-SRP-35-0050 is related to this service bulletin. Boeing Fleet Team Digest (FTD) 707 FTD 35-12001 is related to this service bulletin. This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected Yes Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected Yes Publications Affected

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 5 of 28**Reference Affected**  **Planning Data** Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator Yes Operator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**ACTION (PRR 18115-RS)** Remove applicable ceiling and sidewall lining panels in the flight compartment as needed to gain access to the affected low pressure oxygen flex hoses and replace conductive hoses with new non-conductive hoses. Perform leak detection procedure and functional test the oxygen system. Install removed ceiling and sidewall panels as needed. **EFFECTIVITY** 707-100, -100B, -200, -300, -300B, -300C, -400, 720, -720B Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s). **COMPLIANCE** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Boeing recommends that the change given in this service bulletin be done within 36 months after the original issue date of this service bulletin. **INDUSTRY SUPPORT INFORMATION** Boeing warranty remedies are not available for the configuration changes given in this service bulletin. **MANPOWER** Refer to Paragraph 1.G., Manpower. **MATERIAL INFORMATION** Operator Supplied Parts/Materials. Refer to Paragraph 2.C.2., for parts and materials supplied by the operator.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 6 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 7 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 8 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**

BLANK PAGE

### Commercial **Airplanes** 

# 707 Service Bulletin **ALERT Number: A3538**  Original Issue: October 02, 2013 ATA System: 3511 3512 **SUBJECT:** OXYGEN - Flight Crew Oxygen System - Low Pressure Oxygen Flex Hose Replacement THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER. **1. PLANNING INFORMATION A. Effectivity**  1. Airplanes This service bulletin is for the airplane(s) shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 18115-RS for data about this change. This service bulletin is for the airplane(s) shown below. Refer to Service Bulletin Index D6-1647 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
**DESCRIPTION CONFIGURATION**  **GROUP** All Airplanes with possible conductive oxygen flex hoses installed

- 1

Airplane Models: 707-100, 707-100B, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B **Group Variable Number**  1 B0001 - B0029 1 B0101 - B0125 1 B0201 - B0203 1 B0301 - B0306 1 B0401 - B0402

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 9 of 28**Group Variable Number**  1 B0501 - B0515 1 B2001 - B2008 1 B2091 - B2092 1 B2101 - B2116 1 B2191 - B2194 1 B2199 1 B2201 - B2227 1 B2401 - B2403 1 B2501 - B2502 1 B2551 - B2553 1 B2601 - B2608 1 00001 - 00002 1 00004 - 00006 1 00101 1 00103 - 00113 1 00115 - 00153 1 00201 - 00205 1 00301 - 00305 1 00401 - 00449 1 00471 - 00475 1 00501 - 00513 1 00601 1 00701 - 00703 1 02001 - 02020 1 02101 - 02121 1 02201 - 02207 1 02301 - 02303 1 02401 - 02418 1 04001 - 04005 1 04020 - 04022 1 04101 - 04106 1 04201 - 04218 1 04271 - 04272

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 10 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT Group**  **Variable Number** 1 04301 - 04303 1 05001 - 05060 1 05101 - 05138 1 05201 - 05208 1 05301 - 05312 1 05401 1 05601 - 05605 1 05631 - 05635 1 05701 - 05703 1 05801 - 05802 1 05821 - 05827 1 05831 - 05833 1 05851 - 05854 1 05891 - 05892 1 05921 - 05923 1 05941 - 05942 1 05961 - 05970 1 06001 - 06002 1 06101 1 06401 - 06404 1 06451 1 06461 1 07001 - 07017 1 07041 - 07059 1 07071 - 07081 1 07101 - 07109 1 07181 1 07191 1 07201 - 07215 1 07251 - 07271 1 07401 - 07407 1 07451 - 07458 1 07501 - 07504

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 11 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT Group**  **Variable Number** 1 07601 - 07626 1 07661 - 07662 1 07681 - 07684 1 07701 - 07702 1 07801 - 07821 1 07901 - 07907 1 08001 - 08008 1 08021 1 08051 - 08056 1 08071 - 08077 1 08101 - 08104 1 08121 - 08129 1 08141 - 08144 1 08151 - 08153 1 08171 - 08173 1 08191 - 08192 1 08201 - 08210 1 08221 - 08224 1 08241 - 08244 1 08251 1 08261 1 08271 1 08301 - 08320 1 08324 - 08330 1 08333 1 08401 - 08410 1 08451 - 08452 1 08471 - 08475 1 08501 - 08502 1 08551 - 08553 1 08581 - 08582 1 09001 - 09006 1 09101 - 09107

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 12 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT Group**  **Variable Number** 1 09161 - 09167 1 09201 - 09204 1 09221 - 09223 1 09227 1 09231 - 09232 1 09251 1 09271 1 09281 1 09286 - 09290 1 09411 1 09421 1 09438 1 09441 2. Spares Affected Examine your spares supply for the parts identified below. If any parts are found, refer to Paragraph 2.C.1., Kits/Parts for the recommended action.
**Part Number** 10-60174-24 or -36 **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. If the changes in this service bulletin are not done, an electrical grounding condition can result, causing the hose to melt or burn and release smoke and/or fire into the flight compartment. This service bulletin will replace low pressure oxygen flex hoses with non-conductive low pressure oxygen flex hoses located in the flight compartment. Boeing Service Related Problem (SRP) 707-SRP-35-0050 is related to this service bulletin. Boeing Fleet Team Digest (FTD) 707 FTD 35-12001 is related to this service bulletin.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 13 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT D. Description**  Remove applicable ceiling and sidewall lining panels in the flight compartment as needed to gain access to the affected low pressure oxygen flex hoses and replace conductive hoses with new non-conductive hoses. Install removed ceiling and sidewall panels as needed and functional test the oxygen system. The work in this service bulletin is done in the maintenance zone(s) given below.
**Affected Maintenance Zones Zone**  **Model** 2-21, 2-22, 2-23 707-100, 707-100B, 707-200, 707-300, 707-300B, 707-300C, 707-400, 720, 720B **E. Compliance** The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory. Boeing recommends that the change given in this service bulletin be done within 36 months after the original issue date of this service bulletin. **F. Approval** This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified in this service bulletin comply with the applicable regulations and are FAA approved, as well as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as modified by other 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 task 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 task 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 inspect the work • Time to cure the materials • Time to make the parts • Time to find the tools.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 14 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT Elapsed Hours**  **Task Hours Number of Persons**  **Task** 3.10 6.20 2 Open Access 1.00 1.00 1 Figure 1 1.00 1.00 1 Figure 2 1.00 1.00 1 Figure 3 1.00 1.00 1 Figure 4 0.55 0.55 1 Test 3.00 6.00 2 Close Access 10.65 16.75 TOTAL FOR EACH AIRPLANE

**H. Weight and Balance Changes** None. **I. Electrical Load Data** Not applicable. **J. References** 1. Existing Data: a. Engineering Change Memo PRR 18115-RS b. Service Related Problem (SRP) 707-SRP-35-0050 c. Fleet Team Digest 707 FTD 35-12001 d. 707 Maintenance Manual (AMM) Subject 35-0-0, 35-1-0, 25-2-31 2. Data Supplied with this Service Bulletin: None. 3. Installation Drawings Used in the Preparation of this Service Bulletin:
**Title Drawing Number**  TUBING INSTL. - OXYGEN SEC. 41 65-01656 PROD. ILLUST. TUBING INSTL. - SECTION 41. CAPTAIN AND FIRST OFFICER 50-2541- 5PI Sheets 21-10, 21-11, 21-12, 21-13, 21-14, 21-15, 21-16 PROD. ILLUST. TUBING INSTL. - SECTION 41. OBSERVER AND NAVIGATOR 50-2541- 5PI Sheets 23-10, 23-11, 23-12

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 15 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**The table above lists applicable drawings used to prepare this service bulletin. The drawings are not necessary to make the specified changes, and are not supplied with this service bulletin. The drawings may not be applicable to all airplane configurations or operators. **K. Publications Affected** 1. Publications: **Chapter-Section Publication**  35-1 707 Illustrated Parts Catalog 2. Damage Tolerance Based Structural Inspections: – Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the Maintenance Program. This service bulletin does not affect FCS, therefore DTIs are not necessary. **L. Interchangeability and Intermixability of Parts** Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability information. **M. Software Accomplishment Summary** Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 16 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT 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 Inspect the airplane to determine the flight crew oxygen system configuration. Refer to the Table in 2.C.2., and for each crew member location found determine if a new oxygen flex hose assembly is required. The total number of hose assemblies 60B50059-642 required to change one airplane is the sum of the individual locations with hose assemblies requiring replacement. 2. Parts and Materials Supplied by the Operator The following parts or materials are necessary to do the change in this service bulletin. Parts and materials in the manuals given in Paragraph 1.J., References, can also be necessary. Examine operator part and material supply to make sure all necessary parts and materials are available.
**Notes Existing Part Number**  **Name QTY**  **Part Number / Specification**  Captain 10-60174-24 or 37001- 642 (a), (c), (d), (e) Hose Assembly (36 inch) 1 60B50059-642 (b), (f) 1st Officer 10-60174-24 or 37001- 642 (a), (c), (d), (e) Hose Assembly (36 inch) 1 60B50059-642 (b), (f) Observer 10-60174-24 or 37001- 642 (a), (c), (d), (e) Hose Assembly (36 inch) 1 60B50059-642 (b), (f) Navigator 10-60174-24 or 37001- 642 (a), (c), (d), (e) Hose Assembly (36 inch) 1 60B50059-642 (b), (f) (a) Existing optional part number 10-60174-36 or 37001-36. (b) Hydraflow, 1881 W. Malvern Ave., Fullerton, CA., 92833-2403 (USA) , Cage Code 24984, TEL: (714) 773-2600, FAX: (714) 773-6351, email: www.hydraflowusa.com. (c) This part is not used in production. (d) Discard the existing part. (e) You can not use the existing part to replace the new or changed part. (f) Supplier part number 38001- 642.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 17 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**3. Parts Modified and Reidentified None. 4. Parts Removed and Not Replaced None. **D. Parts Necessary to Change Spares** None. **E. Special Tooling - Price and Availability** None. **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 18 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT 3. ACCOMPLISHMENT INSTRUCTIONS**  **A. GENERAL INFORMATION CAUTION:**  KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL, METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR OTHER ELECTRICAL DAMAGE. **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. Unless shown differently, these dimensions and tolerances are used: – Torque limits to tighten nuts and bolts are in SRM Chapter 51 4. These work instructions refer to procedures included in other Boeing documents. When the words "refer to" are used and the operator has an accepted alternative procedure, the accepted alternative procedure can be used. When the words "in accordance with" are included in the instruction, the procedure in the Boeing document must be used. 5. The instructions in Paragraph 3.B., Work Instructions and the figures can include operation of tools or test equipment. Boeing Engineering Tool Drawings, the Illustrated Tool and Equipment Manual, and the Special Tool and Ground Handling Drawing Index contain data on versions of the tools or test equipment that you can use. It is permitted to use replaced tools. It is not permitted to use superseded tools. 6. If it is necessary to remove more parts for access, you can remove those parts. If you can get access without removing identified parts, it is not necessary to remove all of the identified parts. Jacking and shoring limitations must be observed. 7. This service bulletin includes functional test procedures for the systems changed by this service bulletin. More functional tests can possibly be necessary in accordance with standard maintenance practices because of interruption to other airplane systems. 8. Shaded areas in Figures are to separate the non-critical and non-authoritative information from the critical and authoritative information. **B. WORK INSTRUCTIONS CAUTION:**  OXYGEN SYSTEM COMPONENTS REQUIRE SPECIAL CARE AND HANDLING PROCEDURES. REVIEW THE SAFETY AND MAINTENANCE PROCEDURES SHOWN IN 707 AMM 35-0-0. 1. Remove sidewall and ceiling panels as needed to gain access to the applicable oxygen flex hose. Refer to 707 AMM 25-2-31 as an accepted procedure. a. For the Captain and First Officer locations, refer to Figures 1 and 2.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 19 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**b. For the Observer and Navigator locations, refer to Figures 3 and 4. 2. Turn off and depressurize the crew oxygen system, refer to 707 AMM 35-1-0 as an accepted procedure. 3. Remove the existing conductive oxygen hose assemblies in accordance with Figures 1, 2, 3, and 4. **NOTE:** Ensure the hose assembly elbows and unions do not move during hose removal. Orientation of the elbows and unions are essential in maintaining proper clearances with other structure. 4. Install the applicable new non-conductive oxygen hose assemblies in accordance with Figures 1, 2, 3, and 4. **NOTE:** Ensure the hose assembly elbows and unions do not move during hose installation. Orientation of the elbows and unions are essential in maintaining proper clearances with other structure. 5. Turn on and pressurize the crew oxygen system, refer to 707 AMM 35-1-0 as an accepted procedure. 6. Do a leak detection procedure on the new non-conductive oxygen hose and functional test the flight crew oxygen system, refer to 707 AMM 35-1-0 as an accepted procedure. 7. Install removed sidewall and ceiling panels as applicable, refer to 707 AMM 25-2-31 as an accepted procedure. 8. Put the airplane back to a serviceable condition.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 20 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.

**FIGURE 1: FLIGHT COMPARTMENT - CAPTAINS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 21 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** Refer to 707 AM 35- 0-0 as an accepted procedure. 1 10-60174-24 HOSE ASSEMBLY Remove 1

Refer to 707 AM 35- 0-0 as an accepted procedure. 1 60B50059-642 HOSE ASSEMBLY Install (New) 2

**FIGURE 1: FLIGHT COMPARTMENT - CAPTAINS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 22 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.

**FIGURE 2: FLIGHT COMPARTMENT - FIRST OFFICERS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 23 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** Refer to 707 AM 35- 0-0 as an accepted procedure. 1 10-60174-24 HOSE ASSEMBLY Remove 1

Refer to 707 AM 35- 0-0 as an accepted procedure. 1 60B50059-642 HOSE ASSEMBLY Install (New) 2

**FIGURE 2: FLIGHT COMPARTMENT - FIRST OFFICERS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 24 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.

**FIGURE 3: FLIGHT COMPARTMENT - OBSERVERS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 25 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** Refer to 707 AM 35- 0-0 as an accepted procedure. 1 10-60174-24 HOSE ASSEMBLY Remove 1

Refer to 707 AM 35- 0-0 as an accepted procedure. 1 60B50059-642 HOSE ASSEMBLY Install (New) 2

**FIGURE 3: FLIGHT COMPARTMENT - OBSERVERS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 26 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY numbers shown below are the number of parts necessary for this figure.

**FIGURE 4: FLIGHT COMPARTMENT - NAVIGATORS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 1 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 27 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT More Data**  **Qty Identification**  **Name Task**  **Step** Refer to 707 AM 35- 0-0 as an accepted procedure. 1 10-60174-24 HOSE ASSEMBLY Remove 1

Refer to 707 AM 35- 0-0 as an accepted procedure. 1 60B50059-642 HOSE ASSEMBLY Install (New) 2

**FIGURE 4: FLIGHT COMPARTMENT - NAVIGATORS OXYGEN HOSE ASSEMBLY - REPLACEMENT (SHEET 2 OF 2)**  Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: October 02, 2013 A3538 28 of 28 **BOEING SERVICE BULLETIN A3538 ALERT**  **ALERT**