# Boeing Alert Service Bulletin 777-35A0027: Revision 1

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2012-0104; AD 2012-13-05 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin 777-35A0027](https://openairdocs.org/service-documents/boeing/777-35a0027.md)
- Title as filed: U.S. DOT/FAA - Service Bulletin - 777-35A0027-01
- Pages: 48
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## Text

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### Page 1

Commercial 
Airplanes
777
Service Bulletin
ALERT
Number: 777-35A0027
Original Issue: December 15, 2011
Revision 1: April 19, 2012
ATA System: 3511
SUBJECT: OXYGEN - Crew Oxygen System - Low Pressure Oxygen 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.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 2011 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Unpublished Work.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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management
Company.
Original Issue: December 15, 2011
777-35A0027Revision 1: April 19, 2012
1 of 48
3.0

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Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
1. PLANNING INFORMATION ........................................ 1 1
A. Effectivity ............................................... 1 1
1. Airplanes ............................................ 1 1
2. Spares Affected ........................................ 1 5
B. Concurrent Requirements ...................................... 1 6
C. Reason ................................................ 1 6
D. Description .............................................. 1 6
E. Compliance .............................................. 1 6
F. Approval ............................................... 1 7
G. Manpower .............................................. 1 7
H. Weight and Balance Changes .................................... 1 7
I. Electrical Load Data ......................................... 1 8
J. References .............................................. 1 8
1. Existing Data: ......................................... 1 8
2. Data Supplied with this Service Bulletin: ........................... 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 8
K. Publications Affected ........................................ 1 9
L. Interchangeability and Intermixability of Parts ........................... 1 9
M. Software Accomplishment Summary ................................ 1 9
2. MATERIAL INFORMATION ........................................ 2 1
A. Material - Price and Availability ................................... 2 1
B. Industry Support Information .................................... 2 1
C. Parts Necessary for Each Airplane ................................. 2 2
1. Kits/Parts ............................................ 2 2
2. Parts and Materials Supplied by the Operator ........................ 2 2
3. Parts Modified and Reidentified ................................ 2 3
4. Parts Removed and Not Replaced .............................. 2 3
D. Parts Necessary to Change Spares ................................. 2 3
E. Special Tooling - Price and Availability ............................... 2 3
F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5
A. GENERAL INFORMATION ..................................... 2 5
B. WORK INSTRUCTIONS ....................................... 2 6
FIGURE 1: LOW PRESSURE OXYGEN HOSE SLEEVE AND TAPE INSTALLATION ......... 2 7
FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS . 30
FIGURE 3: CAPTAIN OXYGEN STOWAGE BOX LOW PRESSURE OXYGEN HOSE REPLACEMENT
.................................................. 3 4
FIGURE 4: FIRST OFFICER STOWAGE CLOSET LOW PRESSURE OXYGEN HOSE REPLACEMENT
.................................................. 3 7
FIGURE 5: OBSERVERS CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENT ..... 4 0
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION ......................... 4 3
APPENDIX A: OXYGEN HOSE TO STOWAGE BOX INSTALLATION ................... 4 8
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Commercial 
Airplanes
777
Service Bulletin
ALERT
Revision Transmittal SheetNumber: 777-35A0027Original Issue: December 15, 2011
Revision 1: April 19, 2012
ATA System: 3511
SUBJECT: OXYGEN - Crew Oxygen System - Low Pressure Oxygen Hose Replacement
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
No more work is necessary on the airplane(s) changed in accordance with the original issue of this service
bulletin.
REASON FOR REVISION
This revision is sent to revise the effected airplanes. This revision removes airplanes that had the intent of this
change incorporated in production.
These sections were changed:
1. Paragraph 1.A., Effectivity, Removed Airplanes.
2. Summary, Industry Support Information, Updated warranty information.
3. Paragraph 2.A., Material Price and Availability, Updated Price.
4. Paragraph 2.B., Industry Support Information; Updated warranty information.
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
December 15, 2011Original Issue:
April 19, 2012Revision 1:
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Commercial 
Airplanes
777
Service Bulletin
ALERT
SummaryNumber: 777-35A0027Original Issue: December 15, 2011
Revision 1: April 19, 2012
ATA System: 3511
SUBJECT: OXYGEN - Crew Oxygen System - Low Pressure Oxygen 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 hoses that
may be subjected to electrical current. An electrical current condition in the low pressure oxygen hose can cause
the low pressure oxygen hose to melt or burn. This could result in smoke and/or fire in the flight compartment.
An operator reported that a fire originated near the first officer's area which caused extensive damage to the
flight deck. One scenario of the causes being considered is that an electrical fault or short circuit resulted in
electrical heating of the low pressure oxygen hoses in the flight crew oxygen system.
This service bulletin will replace low pressure oxygen hoses with non-conductive low pressure oxygen hoses
located on the flight deck. The replacement of the low pressure oxygen hoses will prevent electrical current from
passing through the low pressure oxygen hose internal anti-collapse spring which can cause the low pressure
oxygen hose to melt or burn.
Boeing Service Related Problem (SRP) 777-SRP-35-0047 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 35-11003 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 AffectedYesSpares Affected
Paragraph 1.E., ComplianceYesAD Related
Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change
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ReferenceAffectedPlanning Data
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedYesPublications Affected
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsYesKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
YesOperator Supplied Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION (PRR 62359)
Remove the stowage boxes for the oxygen masks. Remove the First Officer forward console and side console.
Replace the existing low pressure oxygen hoses with the new non-conductive low pressure oxygen hoses.
Perform a leak test.
EFFECTIVITY
777-200, -200LR, -300, -300ER, 777F, Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected
airplanes.
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 18 months after the original
issue date of this service bulletin.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-279-AD, is related to
this service bulletin.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are available for 777 airplanes in-warranty as of September 30, 2011. For man-hour
reimbursement for airplanes in-warranty as of that date, send a warranty claim to Boeing Warranty & Product
Assurance Contracts. The kit for airplanes in-warranty as of that date will be supplied at no-charge. Please also
see BPL 6-1151-777-PGM-198, dated January 6, 2011 for additional participation. Copies of this Program Letter
are available from Boeing Warranty & Product Assurance Contracts.
When placing your no-charge purchase order with Material Management please reference this service bulletin
number, the airplane variable number(s) and this Program Letter 6-1151-777-PGM-198 in your purchase order.
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MANPOWER
Elapsed HoursTotal Task HoursAirplanes
11.2517.75TOTAL FOR
EACH AIR-
PLANE
MATERIAL INFORMATION
Boeing Supplied Kits/Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
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BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
REMOVE THE FIRST OFFICER
FORWARD CONSOLE AND SIDE
CONSOLE TOP. REPLACE THE
LOW PRESSURE OXYGEN HOSE.
PERFORM A LEAK TEST.
REMOVE THE STOWAGE BOXES FOR THE
OXYGEN MASKS. REPLACE THE LOW
PRESSURE OXYGEN HOSES. PERFORM A
LEAK TEST
FWD  2121436
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### Page 11

Commercial 
Airplanes
777
Service Bulletin
ALERT
Number: 777-35A0027
Original Issue: December 15, 2011
Revision 1: April 19, 2012
ATA System: 3511
SUBJECT: OXYGEN - Crew Oxygen System - Low Pressure Oxygen 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
Refer to Service Bulletin Index Document D624T001 Part 3 for Airplane Variable Number,
LineNumber, and Serial Number data.
This service bulletin is for the airplane(s) shown below. An equivalent change is on subsequent
production airplanes. Refer to PRR 62359 for data about this change.
DESCRIPTIONCONFIGURATIONGROUP
All 777 airplanes before L/N 976.-1
Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER, 777F
GroupVariable Number
1WA001 - WA017
1WA076 - WA080
1WA086 - WA093
1WA101 - WA104
1WA116 - WA119
1WA131 - WA137
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GroupVariable Number
1WA171 - WA175
1WA196 - WA198
1WA206 - WA212
1WA221 - WA223
1WA231 - WA232
1WA241 - WA250
1WA261 - WA266
1WA281 - WA283
1WA301 - WA304
1WB001 - WB021
1WB031 - WB046
1WB051 - WB088
1WB101 - WB106
1WB121 - WB125
1WB131 - WB148
1WB151 - WB155
1WB161 - WB177
1WB181 - WB194
1WB201 - WB215
1WB231 - WB247
1WB271 - WB273
1WB276 - WB286
1WB291 - WB302
1WB306 - WB307
1WB311 - WB337
1WB341 - WB342
1WB366 - WB368
1WB371 - WB388
1WB406
1WB411 - WB413
1WB416 - WB439
1WB446 - WB453
1WB476
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GroupVariable Number
1WB481 - WB484
1WB501 - WB512
1WB531 - WB537
1WB551 - WB554
1WB591 - WB597
1WB601 - WB606
1WB611 - WB622
1WB631 - WB638
1WB646 - WB649
1WC051 - WC073
1WC101 - WC104
1WC111 - WC120
1WC221 - WC224
1WC241 - WC243
1WC281 - WC290
1WC301 - WC308
1WC361 - WC364
1WC371 - WC374
1WC381 - WC395
1WC441
1WC446 - WC449
1WC456 - WC459
1WC486 - WC493
1WC506 - WC508
1WC521 - WC522
1WC531 - WC536
1WC546 - WC548
1WC556
1WC566 - WC567
1WC571 - WC574
1WC581
1WD001 - WD002
1WD011 - WD018
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GroupVariable Number
1WD031 - WD036
1WD046 - WD055
1WD066 - WD075
1WD081 - WD089
1WD091
1WD096
1WD101 - WD105
1WD111
1WD116
1WD501 - WD513
1WD521 - WD541
1WD546 - WD554
1WD561 - WD573
1WD581 - WD599
1WD606 - WD609
1WD621 - WD632
1WD651 - WD665
1WD671 - WD677
1WD691 - WD709
1WD741 - WD752
1WD761 - WD771
1WD786 - WD788
1WD796 - WD819
1WD826 - WD837
1WD846 - WD867
1WD871 - WD886
1WD911 - WD915
1WD921 - WD922
1WD936 - WD939
1WD946 - WD953
1WD966 - WD970
1WD981 - WD982
1WD986 - WD987
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GroupVariable Number
1WD996
1WE001 - WE004
1WE011 - WE012
1WE021 - WE026
1WE031 - WE034
1WE051 - WE054
1WE071
1WE081 - WE083
1WE091
1WE126 - WE137
1WE151 - WE153
1WE176 - WE177
1WE186 - WE187
1WE216 - WE217
1WF001 - WF004
1WF016 - WF020
1WF031 - WF033
1WF046 - WF058
1WF075 - WF077
1WF081 - WF088
1WF096 - WF101
1WF106 - WF107
1WF111 - WF113
1WF121 - WF123
1WF131
2. Spares Affected
Examine your spares supply for the parts or components identified below. If any parts or components
are found, refer to Paragraph 3.B., Work Instructions for the recommended action.
Part Number
57034-81220
57034-81320
57034-91100
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B. Concurrent Requirements
None.
C. Reason
The changes provided in this service bulletin will help prevent damage to the low pressure oxygen
hoses that may be subjected to electrical current. An electrical current condition in the low pressure
oxygen hose can cause the low pressure oxygen hose to melt or burn. This could result in smoke
and/or fire in the flight compartment.
An operator reported that a fire originated near the first officer's area which caused extensive damage
to the flight deck. One scenario of the causes being considered is that an electrical fault or short circuit
resulted in electrical heating of the low pressure oxygen hoses in the flight crew oxygen system.
This service bulletin will replace low pressure oxygen hoses with non-conductive low pressure oxygen
hoses located on the flight deck. The replacement of the low pressure oxygen hoses will prevent
electrical current from passing through the low pressure oxygen hose internal anti-collapse spring which
can cause the low pressure oxygen hose to melt or burn.
Boeing Service Related Problem (SRP) 777-SRP-35-0047 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 777 FTD 35-11003 is related to this service bulletin.
D. Description
Remove the stowage boxes for the oxygen masks. Remove the First Officer forward console and side
console. Replace the existing low pressure oxygen hoses with the new non-conductive low pressure
oxygen hoses. Perform a leak test.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
211, 212777-200, 777-200LR, 777-300,
777-300ER, 777F
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 18 months after the
original issue date of this service bulletin.
Federal Aviation Administration (FAA) Notice of Proposed Rule Making NPRM 2011-NM-279-AD, is
related to this service bulletin.
Export Controlled ECCN: 9E991 - BOEING
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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.
Elapsed HoursTask HoursNumber of PersonsTask
0.500.501Open Access
0.750.751Figure 1
2.254.502Figure 2
1.001.001Figure 3
1.501.501Figure 4
1.002.002Figure 5
0.500.501Test
3.256.502Figure 6
0.500.501Close Access
11.2517.75TOTAL FOR EACH AIRPLANE
H. Weight and Balance Changes
Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
+ 48.0 lb-in+ 0.2 lb777-200/-200LR,
777F
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Change in Moment
(Pound-Inches)
Change in Weight
(Pounds)Airplane
+ 3.9 lb-in+ 0.2 lb777-300/-300ER
I. Electrical Load Data
Not changed.
J. References
1. Existing Data:
a. Engineering Change Memo PRR 62359
b. Boeing Program Letter 6-1151-777-PGM-198, dated January 6, 2011
c. Boeing Service Related Problem (SRP) 777-SRP-35-0047
d. Standard Overhaul Practices Manual (SOPM) 20-70-01
e. 777 Aircraft Maintenance Manual (AMM) 25-11-01, 25-15-01, 25-15-03, 25-15-05, 35-00-00,
35-11-18
f. 777 Fleet Team Digest (FTD) 35-11003
2. Data Supplied with this Service Bulletin:
None.
3. Installation Drawings Used in the Preparation of this Service Bulletin:
TitleDrawing Number
Tubing Installation Right Side Cab STA 126.5 - 246208W4100
Tubing Installation Left Side Cab STA 126.5 - 246208W4101
Tubing Installation Flight Deck Partition STA 246208W4103
Lining Installation - No. 3 Window232W1403
Console Installation - Forward232W1405
Console Installation - Side232W1406
Lining Installation - Right Side Aft232W1411
Molding Installation - Aft Lining232W1414
Console Installation - Observer232W4302
Stowage Installation - Right Side232W4305
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.
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### Page 19

K. Publications Affected
1. Publications:
Chapter-SectionPublication
35-11777 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.
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2.    MATERIAL INFORMATION
A. Material - Price and Availability
Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators
are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.
The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.
Prices are in United States Dollars. Terms: Net 30 days.
Reference this service bulletin and submit your purchase order by one of these methods:
1. Order on-line via ATA Spec 2000 or The Boeing PART Page
2. Fax to (206) 662-7145
REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER
AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION
Unit Price as of
the original issue
date of this Ser-
vice Bulletin (US
Dollars)
ROLT as of the
original issue
date of this Ser-
vice Bulletin (Cal-
endar Days)
QTYDateNameKit Number
$1066.00149111/22/2011Top Kit005W3527-1
661/09/2012Top Kit005W3527-1
661/16/2012Top Kit005W3527-1
661/23/2012Top Kit005W3527-1
661/30/2012Top Kit005W3527-1
662/06/2012Top Kit005W3527-1
662/13/2012Top Kit005W3527-1
662/20/2012Top Kit005W3527-1
662/27/2012Top Kit005W3527-1
663/05/2012Top Kit005W3527-1
663/12/2012Top Kit005W3527-1
663/19/2012Top Kit005W3527-1
633/26/2012Top Kit005W3527-1
B. Industry Support Information
Boeing warranty remedies are available for 777 airplanes in-warranty as of September 30, 2011. For
man-hour reimbursement for airplanes in-warranty as of that date, send a warranty claim to Boeing
Warranty & Product Assurance Contracts. The kit for airplanes in-warranty as of that date will be
supplied at no-charge. Please also see BPL 6-1151-777-PGM-198, dated January 6, 2011 for additional
participation. Copies of this Program Letter are available from Boeing Warranty & Product Assurance
Contracts.
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### Page 22

When placing your no-charge purchase order with Material Management please reference this service
bulletin number, the airplane variable number(s) and this Program Letter 6-1151-777-PGM-198 in your
purchase order.
C. Parts Necessary for Each Airplane
1. Kits/Parts
To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.
NOTE: One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by
the Operator, are necessary for each airplane. The Top Kit is divided into Figure kits for
each installation figure shown in the table below.
Figure Kit
54321Top Kit
11111005W3527-1
ALL
KIT 005W3527-1
Notes
Existing Part
NumberName
Figure
New Part Number
54321
Qty
(a) (b)SLEEVE....3232U8002-723
(a) (b)SLEEVE....1232U8002-731
(a) (c)57034-81220HOSE ASSY.111.57034-33N040220
(a) (c)57034-81320HOSE ASSY1....57034-33N040320
(a) (c)57034-91100HOSE ASSY...1.57034-34N040100
(a) This part is used in production.
(b) The sleeve is made from BMS 13-52 Type V. This may come in colors of black or white.
(c) You cannot use the existing part to replace the new or changed part.
2. Parts and Materials Supplied by the Operator
NotesNameQTYPart Number
(a)P29 Tape-P29 - 1 inch wide,
color optional
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NotesNameQTYPart Number
(a) XPEDX, 7011 South 118th Street, Kent, WA 98032; Phone: 425-251-5300
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.
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### Page 24

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PROPRIETARY - Copyright © Unpublished
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ALERTALERT
BLANK PAGE

### Page 25

3.    ACCOMPLISHMENT INSTRUCTIONS
A. GENERAL INFORMATION
CAUTION: READ AND OBEY THE SAFETY PRECAUTIONARY AND GENERAL INSTRUCTIONS
FOR THE OXYGEN SYSTEM BEFORE YOU DO THE MAINTENANCE. REF TO 777
AMM 35-00-00 AS AN ACCEPTED PROCEDURE.
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:
– Linear dimensions are in inches
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus
or minus 0.03 inch
– Torque limits to tighten nuts and bolts are in SRM Chapter 51
4. Use the approved fastener and process material substitutions in accordance with
SRM Chapter 51.
5. If the length of any fastener specified in this service bulletin does not meet installation
standards given in SRM Chapter 51, then a fastener of the same specification, or
an approved substitute, with a length which meets the installation standards given
in SRM Chapter 51 may be used. In addition, washers may be installed for fastener
grip length in accordance with SRM Chapter 51.
6. 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.
7. 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.
8. Where the work instructions include installation of a kept part, a new or serviceable
part with the same part number can be installed as an alternative to the kept part.
9. 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.
10. Oxygen hose replacement may be done in any order after installation of sleeving.
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### Page 26

B. WORK INSTRUCTIONS
WARNING: DO NOT PERMIT OIL, GREASE, DIRT OR OTHER FLAMMABLE MATERIALS TO GET
NEAR THE PRESSURE OXYGEN SYSTEM. THESE MATERIALS CAN CAUSE A FIRE
OR AN EXPLOSION WHEN THEY ARE NEAR PRESSURIZED OXYGEN.
CAUTION: SPECIAL CARE MUST BE USED WHEN OXYGEN COMPONENTS ARE HANDLED
AND WORKED WITH. BEFORE WORK IS DONE OF THE OXYGEN SYSTEM, READ
THE SAFETY AND MAINTENANCE PROCEDURES. REFER TO 777 AMM 35-00-00
AND SOPM 20-70-01 AS ACCEPTED PROCEDURES.
CAUTION: USE ONLY OXYGEN CLEAN COMPONENTS IN THE OXYGEN SYSTEM. IF YOU DO
NOT USE OXYGEN CLEAN COMPONENTS, A FIRE OR EXPLOSION CAN OCCUR.
THIS CAN CAUSE DAMAGE TO EQUIPMENT OR INJURIES TO PERSONS.
CAUTION: MAXIMUM PERMITTED OPEN TIME FOR OXYGEN TUBES, HOSES AND
COMPONENTS IS 5 MINUTES.
CAUTION: KEEP A GAP BETWEEN THE ELECTRICAL WIRING AND THE OXYGEN HOSES TO
PREVENT CHAFFING. THIS CAN CAUSE DAMAGE TO THE ELECTRICAL WIRING
OR OXYGEN HOSES. REFER TO 777 AMM 35-00-00 AS AN ACCEPTED PROCEDURE.
1. Install sleeves and tape on low pressure oxygen hoses 57034-33N040220 and 57034-33N040320
in accordance with FIGURE 1.
NOTE: Sleeve installation is not required on low pressure oxygen hose 57034-34N040100.
2. Remove the first officer's seat. Refer to 777 AMM 25-11-01 as an accepted procedure. - OPTIONAL
This step improves access to the area but is not required.
3. Replace two low pressure oxygen hoses in the first officer side console in accordance with FIGURE
2.
4. Replace low pressure oxygen hose in the captain forward console interface in accordance with
FIGURE 3.
5. Replace low pressure oxygen hose in the first officer stowage closet in accordance with FIGURE
4.
6. Replace low pressure oxygen hose in the observers console in accordance with FIGURE 5.
7. Perform leak test. Refer to 777 AMM 35-00-00 as an accepted procedure.
8. Restore flight deck interior in accordance with FIGURE 6
9. If removed, install the first officer's seat. Refer to 777 AMM 25-11-01 as an accepted procedure.
10. Put the airplane back into a serviceable condition.
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BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
1.25
1.00
O.7C
0.30~  LOW PRESSURE
OXYGEN HOSE
(TYPICAL)  FITTING
1.00 -  TAPE  SLEEVE
1.25
END OF
SLEEVE
1.25
1.00
0.70
LOW PRESSURE  0.30
OXYGEN HOSE
PART MARK
SLEEVE  TAPE  1.00  FITTING
1.25  (TYPICAL)
END OF
SLEEVE
57034-33N040320
2121001
FIGURE 1: LOW PRESSURE OXYGEN HOSE SLEEVE AND TAPE INSTALLATION
(SHEET 1 OF 3)
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### Page 28 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
1.25
0.70
0.30  LOW PRESSURE
OXYGEN HOSE
(TYPICAL)  FITTING
1.00  TAPE  SLEEVE
1.25
END OF
SLEEVE
1.25
1.00
0.70
LOW PRESSURE  0.30
OXYGEN HOSE
PART MARK
SLEEVE  TAPE  1:25  FITTING
(TYPICAL)
END OF
SLEEVE
57034-33N040220
2121028
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 each airplane.
FIGURE 1: LOW PRESSURE OXYGEN HOSE SLEEVE AND TAPE INSTALLATION
(SHEET 2 OF 3)
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Work - See page 1 for details.  28 of 48

### Page 29

More DataQtyIdentificationNameTaskStep
(a)1232U8002-731SLEEVEInstall (New)1
Install on 57034-
33N040320 oxygen
hose.
(a)3232U8002-723SLEEVEInstall (New)2
Install on 57034-
33N040220 oxygen
hoses
(b)--TapeApply3
P29 Tape - 1 inch
wide
On each end of the
sleeve.
(a) Cut sleeve with hot knife or other heated tool as needed.
(b) Apply 2 to 3 layers of tape. After wrapping maximum width of wrapped tape is 1.25 inches.
FIGURE 1: LOW PRESSURE OXYGEN HOSE SLEEVE AND TAPE INSTALLATION
(SHEET 3 OF 3)
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BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
2121040
FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS
(SHEET 1 OF 4)
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### Page 31 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
2121113
FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS
(SHEET 2 OF 4)
Original Issue: December 15, 2011
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Work - See page 1 for details.  31 of 48

### Page 32

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 each airplane.
More DataQtyIdentificationNameTaskStep
Refer to 777 AMM
25-15-03 as an ac-
cepted procedure.
(a)
--First Officer Forward
Console
Remove / Keep1
Refer to 777 AMM
35-11-18 as an ac-
cepted procedure.
Oxygen masks do
not need to be re-
moved.
--Stowage Box AssemblyRemove / Keep2
Remove Upper Part
only of Side Console
Top. Refer to 777
AMM 25-15-01 as
an accepted proce-
dure.
--First Officer Side Con-
sole Top
Remove / Keep3
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
157034-91100HOSE ASSYRemove4
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
157034-34N040100HOSE ASSYInstall (New)5
Loose install First
Officer Side Console
Top. (b)
--First Officer Side Con-
sole Top
Install (Temporary)6
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
157034-81220HOSE ASSYRemove7
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
Refer to APPENDIX
A for more informa-
tion.
157034-33N040220HOSE ASSYInstall (New)8
Do not install
Stowage Box. Insert
Stowage Box and
leave in place. (b)
--Stowage Box AssemblyInsert9
FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS
(SHEET 3 OF 4)
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### Page 33

More DataQtyIdentificationNameTaskStep
(a) The first officer forward console can be loosened and lifted a minimal amount to access the fasteners on
the first officer side console top. For airplanes with an Electronic Flight Bag (EFB) installed, removal of
the EFB display unit is not required.
(b) Final installation will be done after the leak test.
FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS
(SHEET 4 OF 4)
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BOEING SERVICE BULLETIN 777-35A0027
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### Page 34 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
2121139
FIGURE 3: CAPTAIN OXYGEN STOWAGE BOX LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 1 OF 3)
Original Issue: December 15, 2011
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### Page 35

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 each airplane.
FIGURE 3: CAPTAIN OXYGEN STOWAGE BOX LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 2 OF 3)
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ALERTALERT

### Page 36

More DataQtyIdentificationNameTaskStep
Refer to 777 AMM
35-11-18 as an ac-
cepted procedure.
Oxygen masks do
not need to be re-
moved.
--Stowage Box AssemblyRemove / Keep1
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
157034-81220HOSE ASSYRemove2
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
Refer to APPENDIX
A for more informa-
tion.
157034-33N040220HOSE ASSYInstall (New)3
Do not install
Stowage Box. Insert
Stowage Box and
leave in place. (a)
--Stowage Box AssemblyInsert4
(a) Final installation will be done after the leak test.
FIGURE 3: CAPTAIN OXYGEN STOWAGE BOX LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 3 OF 3)
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ALERTALERT

### Page 37 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
AND B
-WD
2121348
FIGURE 4: FIRST OFFICER STOWAGE CLOSET LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 1 OF 3)
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### Page 38 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
•C FOR REAR VIEW
2121355
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 each airplane.
FIGURE 4: FIRST OFFICER STOWAGE CLOSET LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 2 OF 3)
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Work - See page 1 for details.  38 of 48

### Page 39

More DataQtyIdentificationNameTaskStep
--Close Out SealRemove / Keep1
9-ScrewsRemove / Keep2
--Flight Deck LiningRemove / Keep3
Refer to 777 AMM
35-11-18 as an ac-
cepted procedure.
Oxygen masks do
not need to be re-
moved.
--Stowage Box AssemblyRemove / Keep4
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
157034-81220HOSE ASSYRemove5
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
Refer to APPENDIX
A for more informa-
tion.
157034-33N040220HOSE ASSYInstall (New)6
Do not install
Stowage Box. Insert
Stowage Box and
leave in place. (a)
--Stowage Box AssemblyInsert7
(a) Final installation will be done after the leak test.
FIGURE 4: FIRST OFFICER STOWAGE CLOSET LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 3 OF 3)
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BOEING SERVICE BULLETIN 777-35A0027
ALERTALERT

### Page 40 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
SECOND
OBSERVER
SEAT
OBSERVER'S
CONSOLE
FIRST
OBSERVER
SEAT
FWD
FLIGHT COMPARTMENT
• FOR REAR
VIEW
2121387
FIGURE 5: OBSERVERS CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 1 OF 3)
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### Page 41 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
2121390
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 each airplane.
FIGURE 5: OBSERVERS CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 2 OF 3)
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### Page 42

More DataQtyIdentificationNameTaskStep
Refer to 777 AMM
35-11-18 as an ac-
cepted procedure.
Oxygen masks do
not need to be re-
moved.
--Stowage Box AssemblyRemove / Keep1
(a) (b) (c) Move Ob-
server Console
away from wall to
gain access to oxy-
gen hose. Refer to
777 AMM 25-15-05
as an accepted pro-
cedure.
--Observers ConsoleMove2
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
157034-81320HOSE ASSYRemove3
Refer to 777 AMM
35-00-00 as an ac-
cepted procedure.
Refer to APPENDIX
A for more informa-
tion.
157034-33N040320HOSE ASSYInstall (New)4
Do not install
Stowage Box. Insert
Stowage Box and
leave in place. (d)
--Stowage Box AssemblyInsert5
(a) Optional - For better access, fold Second Observer Seat up to gain access to fasteners holding observer
console to the wall.
(b) Optional - For better access, slide First Observer Seat forward to gain access to fasteners holding observer
console to the wall.
(c) Optional - For better access, rotate top of Observer Console aft and the bottom of Observer Console
forward. This can provide improved access to lower B-Nut.
(d) Final installation will be done after the leak test.
FIGURE 5: OBSERVERS CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENT
(SHEET 3 OF 3)
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ALERTALERT

### Page 43 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
C AND  D
SECOND
OBSERVER
SEAT
OBSERVER'S
CONSOLE
FIRST
OBSERVER
SEAT
FLIGHT COMPARTMENT  FWD  2125483
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION
(SHEET 1 OF 5)
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### Page 44 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
2125490
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION
(SHEET 2 OF 5)
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### Page 45 (OCR)

BOEING SERVICE BULLETIN 777-35A0027
ALERT  ALERT
5
FWD  2125588
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION
(SHEET 3 OF 5)
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### Page 46

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 each airplane.
More DataQtyIdentificationNameTaskStep
Install Upper Part of
Side Console Top.
Refer to 777 AMM
25-15-01 as an ac-
cepted procedure.
--First Officer Side Con-
sole Top
Install (Kept)1
Refer to 777 AMM
25-15-03 as an ac-
cepted procedure.
--First Officer Forward
Console
Install (Kept)2
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION
(SHEET 4 OF 5)
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ALERTALERT

### Page 47

More DataQtyIdentificationNameTaskStep
Refer to 777 AMM
25-15-05 as an ac-
cepted procedure.
Only insert the
Stowage Box.
--Observers ConsoleInstall (Kept)3
--Flight Deck LiningInstall (Kept)4
9-ScrewsInstall (Kept)5
--Close Out SealInstall (Kept)6
Refer to 777 AMM
35-11-18 as an ac-
cepted procedure.
4-Stowage Box AssemblyInstall (Kept)7
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION
(SHEET 5 OF 5)
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BOEING SERVICE BULLETIN 777-35A0027
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### Page 48

1. Torque B-Nut to 190 +2/-9 inch-lbs. Refer to AMM 35-00-00 as an accepted procedure.
2. Ensure a 0.002 inch minimum clearance between B-Nut and Stowage Box fitting. See the figure below.
APPENDIX A:  OXYGEN HOSE TO STOWAGE BOX INSTALLATION
(SHEET 1 OF 1)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: December 15, 2011
777-35A0027Revision 1 April 19, 2012
48 of 48
BOEING SERVICE BULLETIN 777-35A0027
ALERTALERT

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