# Boeing Alert Service Bulletin 757-35A0016: Revision 1

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2009-0795; AD 2010-06-17 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 757-35A0016](https://openairdocs.org/service-documents/boeing/757-35a0016.md)
- Title as filed: Boeing Service Bulletin (2)
- Pages: 25
- PDF: https://openairdocs.org/files/sha256/5e/83/5e83a62d6927f92b1a61a7c5ccb89e9baeeedce0771f72bfef6c1271e1448695
- Page: https://openairdocs.org/service-documents/boeing/757-35a0016/file/5e83a62d6927

## Text

Each page's text from the PDF; open the PDF at a page with #page=N.

### Page 1

Commercial
Airplane
Group
757
Service Bulletin
Number: 757-35A0016 Revision Transmittal SheetDate: November 11, 1999
Revision 1: June 15, 2000
ATA System: 3511
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
No more work is necessary on airplanes changed as shown in the initial release of this service bulletin.
REASON FOR REVISION
This revision is sent to advise operators of the following:
The addition of the Joint Airworthiness Requirements (JAR) statement in the Approval section.
The addition of the vendor equivalent part numbers in the Parts Necessary For Each Airplane section.
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: November 11, 1999
Revision 1: June 15, 2000
757-35A0016
Revision Transmittal Page 1 of 1

### Page 2

(No text on this page.)

### Page 3

Commercial
Airplane
Group
757
Service Bulletin
Number: 757-35A0016 SummaryDate: November 11, 1999
Revision 1: June 15, 2000
ATA System: 3511
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 from smoke and/or fire.
One operator has reported damaged oxygen supply
hoses on the 757 in August of 1997. The damage
occurred due to a short circuit in the 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 from smoke and/or
fire.
Boeing Service Related Problem (SRP)
757-SRP-35-0014 is related to this service bulletin.
ACTION (PRR 54530-213)
Remove the crew oxygen boxes. Replace the
existing low pressure hoses with the new
non-conductive hoses. Install the crew oxygen
boxes. Functional test the system.
EFFECTIVITY
757-300 airplanes, line numbers 804, 810, 818, 839,
846, 849, and 855.
NOTE: Service Bulletin 757-35A0015 is effective
for the 757-200 airplanes.
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
Total Elapsed Time
Man-Hours (Hours)
2.5 2.5
MATERIAL INFORMATION
None
757-35A0016
Summary Page 1 of 2

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BOEING SERVICE BULLETIN 757-35A0016
(TYPICAL)
FWD
APPLICABLE
BOX HOSES AS
REPLACE OXYGEN
V07610
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 Summary Page 2 of 2

### Page 5

Commercial
Airplane
Group
757
Service Bulletin
Number: 757-35A0016
Date: November 11, 1999
Revision 1: June 15, 2000
ATA System: 3511
SUBJECT: OXYGEN - Crew Oxygen - Crew Oxygen System Low Pressure Flex Hose Replacement
THIS SERVICE 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
Refer to Service Bulletin Index Document D624N001, 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 54530-213 for data about this change.
Service Bulletin 757-35A0015 is effective for the 757-200 airplanes.
Airplane Models:
757-300
IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER
CONDOR (CDF)
NU701 NU721-NU726
IDENTIFICATION BY VARIABLE NUMBER
NU701 NU721-NU726
2. Spares Affected
None
November 11, 1999 757-35A0016
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BOEING SERVICE BULLETIN 757-35A0016
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 from smoke and/or fire.
One operator has reported damaged oxygen supply hoses on the 757 in August of 1997. The
damage occurred due to a short circuit in the 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 from smoke and/or fire.
Revision 1 is sent to advise operators of the following:
The addition of the Joint Airworthiness Requirements (JAR) statement in the Approval section.
The addition of the vendor equivalent part numbers in the Parts Necessary For Each Airplane
section.
Boeing Service Related Problem (SRP) 757-SRP-35-0014 is related to this service bulletin.
D. Description
Remove the crew oxygen boxes. Replace the existing low pressure hoses with the new
non-conductive hoses. Install the crew oxygen boxes. Functional test the system.
Revision 1 - No more work is necessary on airplanes changed as shown in the initial release of this
service bulletin.
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
Joint Airworthiness Requirements (JAR) compliance status may be found in the Service Bulletin
Index, Section 1.
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.
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 2

### Page 7

BOEING SERVICE BULLETIN 757-35A0016
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.
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 3

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BOEING SERVICE BULLETIN 757-35A0016
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.
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
H. Weight and Balance Changes
None
I. Electrical Load Data
Not changed
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 4

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BOEING SERVICE BULLETIN 757-35A0016
J. References
1. Existing Data:
a. Engineering Change Memo PRR 54530-213
b. Service Related Problem (SRP) 757-35-0014
c. 757 Maintenance Manual (AMM) Subject 12-15-08, 20-41-00, 35-00-00, 35-11-00, 35-11-51
d. Boeing Service Bulletin 757-35A0015, "Oxygen - Crew Oxygen - Crew Oxygen System Low
Pressure Flex Hose Replacement"
2. Data supplied with this service bulletin:
None
3. Installation Drawings Used in the Preparation of This Service Bulletin:
Drawing Number Title
232N8001 OXYGEN MASK INSTL - CREW
208N0000 MANAGEMENT COLLECTOR - TUBING
INSTL - DWG TREE AND GENERAL NOTES
208N4132 TUBING INSTL - UPPER R CAB STA 199.09
- 297
208N4133 TUBING INSTL - UPPER L CAB STA 199.09
- 297
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 Changed
Publication Chapter-Section
757 Maintenance Manual 35-11
757 Illustrated Parts Catalog 35-11
L. Interchangeability and Intermixability of Parts
Refer to Paragraph 2.E., Existing Parts Accountability, for interchangeability and intermixability
information.
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 5

### Page 10

BOEING SERVICE BULLETIN 757-35A0016
BLANK PAGE
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 6

### Page 11

BOEING SERVICE BULLETIN 757-35A0016
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:
None
2. Parts and Materials Supplied by the Operator:
QTY Boeing Part Number / Vendor Part Number Name
(a) 60B50059-606 / 38001-606 (b) Hose Assy
(a) 60B50059-607 / 38001-607 (b) Hose Assy
(a) For hose quantity requirements, see Illustrated Parts Catalog 35-11 for customer specific
configuration.
(b) HydraFlow (V24984)
13259 East 166th Street
Cerritos, CA 90701-2203 (USA)
D. Parts Necessary to Change Spares
None
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 7

### Page 12

BOEING SERVICE BULLETIN 757-35A0016
E. Existing Parts Accountability
The parts shown below are changed as shown in this service bulletin.
Existing Part Number RUC Name QTY New Part Number PNC RC
60B50059-70 DIS Hose Assy (a) 60B50059-606 S A
60B50059-81 DIS Hose Assy (a) 60B50059-607 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.
F. Special Tooling - Price and Availability
None
G. 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.
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 8

### Page 13

BOEING SERVICE BULLETIN 757-35A0016
3. ACCOMPLISHMENT INSTRUCTIONS
GENERAL NOTES
1. The paragraphs identified with a letter give the general work instructions and the necessary tests.
The instructions identified with numbers on the figures give the recommended sequence of steps.
2. Refer to the Boeing Standard Wiring Practices Manuals 20-10-11 and 20-10-12 for the wire
installation procedures.
3. Obey all of the warnings and cautions given in the specified manual sections.
WORK INSTRUCTIONS
CAUTION: OXYGEN SYSTEM COMPONENTS REQUIRE SPECIAL CARE AND HANDLING
PROCEDURES. REVIEW THE SAFETY AND MAINTENANCE PROCESSES
SHOWN IN THE 757 AMM 35-00-00.
A. Remove the oxygen stowage boxes as shown in 757 AMM 35-11-51 or operator's equivalent
procedure.
B. Remove the existing conductive oxygen hoses as shown in Figures 1, 2, 3, 4, and 5.
NOTE: Ensure 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.
C. Install the applicable new non-conductive oxygen hoses as shown in Figures 1, 2, 3, 4, and 5.
D. Install the oxygen stowage boxes as shown in 757 AMM 35-11-51 or operator's equivalent
procedure.
E. Functional test the crew oxygen system as shown in 757 AMM 35-11-00, "Operational Test - Crew
Oxygen Mask/Regulator" or operator's equivalent procedure.
F. Put the airplane back to a serviceable condition.
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 9

### Page 14

BOEING SERVICE BULLETIN 757-35A0016
FIGURE TABLE OF CONTENTS
Title Page
FIGURE 1. OXYGEN BOX HOSE TYPICAL LOCATIONS. ....................... 1 1
FIGURE 2. CAPTAIN AND FIRST OFFICER'S OXYGEN BOX HOSE
REPLACEMENT .............................................. 1 2
FIGURE 3. RIGHT OBSERVER'S SEAT OXYGEN BOX HOSE REPLACEMENT ..... 1 6
FIGURE 4. LEFT OBSERVER'S SEAT OXYGEN BOX HOSE REPLACEMENT . ..... 1 8
FIGURE 5. SUPERNUMERARY OXYGEN BOX HOSE REPLACEMENT. ........... 2 0
November 11, 1999 757-35A0016
Revision 1: June 15, 2000 10

### Page 15

BOEING SERVICE BULLETIN 757-35A0016
FWD
FIGURE 4
FIGURE 3
FIGURE 5
FIGURE 2
SEE
SEE
SEE
SEE
FIGURE 2
SEE
V07611
FIGURE 1. OXYGEN BOX HOSE TYPICAL LOCATIONS
November 11, 1999 SHEET 1 OF 1 757-35A0016
Revision 1: June 15, 2000 11

### Page 16

BOEING SERVICE BULLETIN 757-35A0016
FWDBSEESEE A
FLIGHT COMPARTMENT
V07612
FIGURE 2. CAPTAIN AND FIRST OFFICER'S OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 1 OF 4 757-35A0016
Revision 1: June 15, 2000 12

### Page 17

BOEING SERVICE BULLETIN 757-35A0016
4
32
A
CAPTAIN'S CONSOLE
1
INBD
UP
FWD
V07613
FIGURE 2. CAPTAIN AND FIRST OFFICER'S OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 2 OF 4 757-35A0016
Revision 1: June 15, 2000 13

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BOEING SERVICE BULLETIN 757-35A0016
1
2 3
FIRST OFFICER'S CONSOLE
4
B
INBD
UP
FWD
V07614
FIGURE 2. CAPTAIN AND FIRST OFFICER'S OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 3 OF 4 757-35A0016
Revision 1: June 15, 2000 14

### Page 19

BOEING SERVICE BULLETIN 757-35A0016
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
STEP TASK NAME REFERENCES QTY NOTES
1 Remove /
Keep
Oxygen Box 757 AMM 35-11-51 2 -
2 Remove /
Discard
Hose Assy 757 AMM 35-11-51 2 Discard the Hose Assy after
recording the part number.
3 Install Hose Assy 757 AMM 35-11-51 2 See Existing Parts
Accountability for applicable
Hose Assy.
4 Install /
Kept
Oxygen Box 757 AMM 35-11-51 2 -
FIGURE 2. CAPTAIN AND FIRST OFFICER'S OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 4 OF 4 757-35A0016
Revision 1: June 15, 2000 15

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BOEING SERVICE BULLETIN 757-35A0016
FWD
A
SEE A
32
41
FLIGHT COMPARTMENT
V07615
FIGURE 3. RIGHT OBSERVER'S SEAT OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 1 OF 2 757-35A0016
Revision 1: June 15, 2000 16

### Page 21

BOEING SERVICE BULLETIN 757-35A0016
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
STEP TASK NAME REFERENCES QTY NOTES
1 Remove /
Keep
Oxygen Box 757 AMM 35-11-51 1 -
2 Remove /
Discard
Hose Assy 757 AMM 35-11-51 1 Discard the Hose Assy after
recording the part number.
3 Install Hose Assy 757 AMM 35-11-51 1 See Existing Parts
Accountability for applicable
Hose Assy.
4 Install /
Kept
Oxygen Box 757 AMM 35-11-51 1 -
FIGURE 3. RIGHT OBSERVER'S SEAT OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 2 OF 2 757-35A0016
Revision 1: June 15, 2000 17

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BOEING SERVICE BULLETIN 757-35A0016
FWDSEE A
1
2
4
3
A
FLIGHT COMPARTMENT
FWD
V07617
FIGURE 4. LEFT OBSERVER'S SEAT OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 1 OF 2 757-35A0016
Revision 1: June 15, 2000 18

### Page 23

BOEING SERVICE BULLETIN 757-35A0016
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
STEP TASK NAME REFERENCES QTY NOTES
1 Remove /
Keep
Oxygen Box 757 AMM 35-11-51 1 -
2 Remove /
Discard
Hose Assy 757 AMM 35-11-51 1 Discard the Hose Assy after
recording the part number.
3 Install Hose Assy 757 AMM 35-11-51 1 See Existing Parts
Accountability for applicable
Hose Assy.
4 Install /
Kept
Oxygen Box 757 AMM 35-11-51 1 -
FIGURE 4. LEFT OBSERVER'S SEAT OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 2 OF 2 757-35A0016
Revision 1: June 15, 2000 19

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BOEING SERVICE BULLETIN 757-35A0016
1 4 23
FWD
V07618
The step numbers shown below agree with the numbers shown in the circle symbols in the figure.
STEP TASK NAME REFERENCES QTY NOTES
1 Remove /
Keep
Oxygen Box 757 AMM 35-11-51 1 -
2 Remove /
Discard
Hose Assy 757 AMM 35-11-51 1 Discard the Hose Assy after
recording the part number.
3 Install Hose Assy 757 AMM 35-11-51 1 See Existing Parts
Accountability for applicable
Hose Assy.
4 Install /
Kept
Oxygen Box 757 AMM 35-11-51 1 -
FIGURE 5. SUPERNUMERARY OXYGEN BOX HOSE REPLACEMENT
November 11, 1999 SHEET 1 OF 1 757-35A0016
Revision 1: June 15, 2000 20

### Page 25

Commercial
Airplane
Group
757
Service Bulletin
Number: 757-35A0016 Evaluation FormDate: November 11, 1999
Revision 1: June 15, 2000
ATA System: 3511
Prepared By: Chris Starr
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) 4321 (poor)
Please rate the quality of the illustrations: (good) 4321 (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 Airplane Group
P.O. Box 3707, Mail Stop 2H-37
Seattle, WA 98124-2207

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