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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Number: 777-35-0041 Original Issue: April 08, 2016 ATA System: 3522 SUBJECT: OXYGEN - Passenger Oxygen System - Gaseous - Low-Pressure Oxygen Flex Hoses 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.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2016 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Unpublished Work.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: April 08, 2016 777-35-0041 1 of 127
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 2 of 127 BOEING SERVICE BULLETIN 777-35-0041
BLANK PAGE
Table of Contents
S u m m a r y5
1. PLANNING INFORMATION9
A . E f f e c t i v i t y9
1. Airplanes9
2 . S p a r e s A f f e c t e d ........................................ 1 0 B. Concurrent Requirements ...................................... 1 0 C. Reason ................................................ 1 0 D. Description .............................................. 1 0 E. Compliance .............................................. 1 1 F . A p p r o v a l ............................................... 1 1 G. Manpower .............................................. 1 1 H. Weight and Balance Changes .................................... 1 5 I. Electrical Load Data ......................................... 1 5 J . R e f e r e n c e s .............................................. 1 5
1. Existing Data: ......................................... 1 5
2. Data Supplied with this Service Bulletin: ........................... 1 6
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 6 K. Publications Affected ........................................ 1 6 L. Interchangeability and Intermixability of Parts ........................... 1 6 M. Software Accomplishment Summary ................................ 1 6
2. MATERIAL INFORMATION ........................................ 1 7 A. Material - Price and Availability ................................... 1 7 B. Industry Support Information .................................... 1 8 C. Parts Necessary for Each Airplane ................................. 1 8 1 . K i t s / P a r t s ............................................ 1 8
2. Parts and Materials Supplied by the Operator ........................ 2 6
3. Parts Modified and Reidentified ................................ 2 6
4. Parts Removed and Not Replaced .............................. 2 7 D. Parts Necessary to Change Spares ................................. 2 7 E. Special Tooling - Price and Availability ............................... 2 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 9 A. GENERAL INFORMATION ..................................... 2 9 B. WORK INSTRUCTIONS ....................................... 3 1 FIGURE 1: FORWARD LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 1 - 2 ] ............................................... 3 7 FIGURE 2: FORWARD LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3 - 4 ] ............................................... 4 0 FIGURE 3: FORWARD LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3 ] ................................................ 4 4 FIGURE 4: FORWARD LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 4 ] ................................................ 4 8 FIGURE 5: FORWARD CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 1-2] .................................................. 5 3 FIGURE 6: FORWARD CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] .................................................. 5 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 3 of 127 BOEING SERVICE BULLETIN 777-35-0041
FIGURE 7: FORWARD CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3] .................................................. 6 1 FIGURE 8: FORWARD CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 4] .................................................. 6 3 FIGURE 9: FORWARD RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 1 - 2 ] ............................................... 6 7 FIGURE 10: FORWARD RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3 - 4 ] ............................................... 6 9 FIGURE 11: FORWARD RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3 ] ................................................ 7 3 FIGURE 12: FORWARD RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 4 ] ................................................ 7 7 FIGURE 13: AFT LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 1-2] . 82 FIGURE 14: AFT LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] . 85 FIGURE 15: AFT LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] . 88 FIGURE 16: AFT LEFT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] . 92 FIGURE 17: AFT CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 1] . . 95 FIGURE 18: AFT CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 2] . . 98 FIGURE 19: AFT CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3] . 102 FIGURE 20: AFT CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] . 105 FIGURE 21: AFT CENTER LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 4] . 108 FIGURE 22: AFT RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 1] . 111 FIGURE 23: AFT RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 2] . 114 FIGURE 24: AFT RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] ................................................. 1 1 7 FIGURE 25: AFT RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] ................................................. 1 2 0 FIGURE 26: AFT RIGHT SIDE LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT [Group 3-4] ................................................. 1 2 4 APPENDIX A: PART DEMAND INTENT ................................... 1 2 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 4 of 127 BOEING SERVICE BULLETIN 777-35-0041
Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION SummaryNumber: 777-35-0041Original Issue: April 08, 2016 ATA System: 3522 SUBJECT: OXYGEN - Passenger Oxygen System - Gaseous - Low-Pressure Oxygen Flex Hoses Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin will make sure that the low-pressure oxygen flex hoses in the therapeutic gaseous oxygen system for the passenger cabin are non conductive. If this service bulletin is not done the low-pressure oxygen flex hoses can potentially be conductive, become heated from electrical faults and cause or contribute to an oxygen-fed fire event that could jeopardize continued safe flight and landing.
A Boeing investigation discovered that the low-pressure oxygen flex hoses in the therapeutic gaseous oxygen system can potentially be conductive. The therapeutic gaseous oxygen system is not continuously pressurized and must be activated by the flight crew. Exposure to electrical faults, such as unintended short circuits, can result in localized electrical heating of the low-pressure oxygen flex hoses.
This service bulletin installs low-pressure oxygen flex hoses that are non conductive to make sure no localized electrical heating occurs if exposed to an unintended electrical fault.
Boeing Service Related Problem (SRP) 777-SRP-35-0063 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 35-14003 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 5 of 127
ReferenceAffectedPlanning Data Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsYesKits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION (PRR 62777-105S) Remove main ceiling panels and outboard stowage bin modules to access low-pressure oxygen flex hoses.
Remove existing low-pressure oxygen flex hoses. Install non-conductive low-pressure oxygen flex hoses. Perform Leak Check. Install main ceiling panels and outboard stowage bin modules removed to gain access to low-pressure oxygen flex hoses.
EFFECTIVITY 777-200/300ER Airplane(s) with therapeutic gaseous oxygen system. 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 2250 days after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of September 30, 2011. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Operators are encouraged to complete the survey provided in APPENDIX A of this service bulletin to help Boeing predict the quantity and timing of the Boeing Supplied Kits/Parts.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 6 of 127 BOEING SERVICE BULLETIN 777-35-0041
BOEING SERVICE BULLETIN 777-35-0041
REMOVE MAIN CEILING PANELS AND OUTBOARD STOWAGE BIN MODULES TO ACCESS LOW PRESSURE OXYGEN FLEX HOSES.
REMOVE EXISTING LOW PRESSURE OXYGEN FLEX HOSES INSTALL NON-CONDUCTIVE LOW PRESSURE OXYGEN FLEX HOSES.
PERFORM LEAK CHECK.
INSTALL MAIN CEILING PANELS AND OUTBOARD STOWAGE BIN MODULES REMOVED TO GAIN ACCESS TO LOW PRESSURE OXYGEN FLEX HOSES.
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 8 of 127 BOEING SERVICE BULLETIN 777-35-0041
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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Number: 777-35-0041 Original Issue: April 08, 2016 ATA System: 3522 SUBJECT: OXYGEN - Passenger Oxygen System - Gaseous - Low-Pressure Oxygen Flex Hoses Replacement BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is applicable to 777-200/300ER Airplanes, line numbers 6 to 1221 in 4 Group(s).
The Variable Numbers and Group Information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-105S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP 777-200 Non-Overhead Space Utilization (OSU) Airplanes with non-OSU loop.
-1 777-200 Non-Overhead Space Utilization (OSU) Airplanes with OSU loop.
-2 777-300ER Airplanes with unique low-pressure oxygen hoses configuration.
-3 777-300ER Airplanes with unique low-pressure oxygen hoses configuration.
-4 Airplane Models:
777-200, 777-300ER Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 9 of 127
GroupVariable Number 1WA076 - WA079 1WB001 - WB021 1WB031 - WB042 1WB044 - WB046 1WB411 - WB413 2WC571 - WC574 4WD966 - WD970 3WE071 - WE078 3WE081 - WE084
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason This service bulletin will make sure that the low-pressure oxygen flex hoses in the therapeutic gaseous oxygen system for the passenger cabin are non conductive. If this service bulletin is not done the low-pressure oxygen flex hoses can potentially be conductive, become heated from electrical faults and cause or contribute to an oxygen-fed fire event that could jeopardize continued safe flight and landing.
A Boeing investigation discovered that the low-pressure oxygen flex hoses in the therapeutic gaseous oxygen system can potentially be conductive. The therapeutic gaseous oxygen system is not continuously pressurized and must be activated by the flight crew. Exposure to electrical faults, such as unintended short circuits, can result in localized electrical heating of the low-pressure oxygen flex hoses.
This service bulletin installs low-pressure oxygen flex hoses that are non conductive to make sure no localized electrical heating occurs if exposed to an unintended electrical fault.
Boeing Service Related Problem (SRP) 777-SRP-35-0063 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 35-14003 is related to this service bulletin.
D. Description Remove main ceiling panels and outboard stowage bin modules to access low-pressure oxygen flex hoses. Remove existing low-pressure oxygen flex hoses. Install non-conductive low-pressure oxygen flex hoses. Perform Leak Check. Install main ceiling panels and outboard stowage bin modules removed to gain access to low-pressure oxygen flex hoses.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 10 of 127 BOEING SERVICE BULLETIN 777-35-0041
The work in this service bulletin is done in the maintenance zone(s) given below.
Group 1-2:
Affected Maintenance Zones ZoneModel 223, 224, 233, 234, 253, 254, 263, 264777-200 Group 3-4:
Affected Maintenance Zones ZoneModel 223, 224, 233, 234, 243, 244, 253, 254, 263, 264777-300ER 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 2250 days 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: April 08, 2016 777-35-0041 11 of 127 BOEING SERVICE BULLETIN 777-35-0041
Group 1-2:
Work Package 1 - LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT BETWEEN STA 325
- STA 1105 Elapsed HoursTask HoursNumber of PersonsTask
0.750.751Open Access
1.701.701FIGURE 1
1.101.101FIGURE 5
1.101.101FIGURE 9
0.350.351Do Leak Detection
0.750.751Close Access
5.755.75TOTAL FOR WORK PACKAGE 1 Group 1-2:
Work Package Number 1 can be done at the same time as Work Package Number 2.
Group 3:
Work Package 1 - LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT BETWEEN STA 325
- STA 1105 Elapsed HoursTask HoursNumber of PersonsTask
1.751.751Open Access
1.601.601FIGURE 2
1.501.501FIGURE 3
2.002.001FIGURE 6
1.501.501FIGURE 7
1.601.601FIGURE 10
1.501.501FIGURE 11
0.950.951Do Leak Detection
1.751.751Close Access
14.1514.15TOTAL FOR WORK PACKAGE 1 Group 3:
Work Package Number 1 can be done at the same time as Work Package Number 2.
Group 4:
Work Package 1 - LOW-PRESSURE OXYGEN FLEX HOSES REPLACEMENT BETWEEN STA 325
- STA 1105 Elapsed HoursTask HoursNumber of PersonsTask
2.402.401Open Access Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2016 777-35-0041 12 of 127 BOEING SERVICE BULLETIN 777-35-0041