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.

ECCN: 9E991

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Unpublished Work.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, DreamlinerTM,

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

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with this document unless provided in writing by Boeing. BOEING is a trademark of Boeing Management

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BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 18

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1. Kits/Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Parts and Materials Supplied by the Operator . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Parts Modified and Reidentified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. Parts Removed and Not Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 23

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

FIGURE 1: LOW PRESSURE OXYGEN HOSE SLEEVE AND TAPE INSTALLATION . . . . . . . . . 27

FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS . 30

FIGURE 3: CAPTAIN OXYGEN STOWAGE BOX LOW PRESSURE OXYGEN HOSE REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

FIGURE 4: FIRST OFFICER STOWAGE CLOSET LOW PRESSURE OXYGEN HOSE REPLACEMENT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

FIGURE 5: OBSERVERS CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENT . . . . . 40

FIGURE 6: FLIGHT DECK INTERIOR RESTORATION . . . . . . . . . . . . . . . . . . . . . . . . . 43

APPENDIX A: OXYGEN HOSE TO STOWAGE BOX INSTALLATION . . . . . . . . . . . . . . . . . . . 48

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Commercial 

Airplanes 777

Service Bulletin

ALERT

Revision Transmittal Sheet 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 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

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BLANK PAGE
Commercial 

Airplanes 777

Service Bulletin

ALERT

Summary 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.

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.

Planning Data Affected Reference

Spares Affected Yes Paragraph 1.A.2., Spares Affected

AD Related Yes Paragraph 1.E., Compliance

Weight and Balance Change Yes Paragraph 1.H., Weight and Balance Changes

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Planning Data Affected Reference

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected Yes Paragraph 1.K., Publications Affected

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required Yes Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Material Yes

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

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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ALERT ALERT
MANPOWER

Airplanes Total Task Hours Elapsed Hours

TOTAL FOR 17.75 11.25

EACH AIRPLANE

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

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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.

GROUP CONFIGURATION DESCRIPTION

1 - All 777 airplanes before L/N 976.

Airplane Models:

777-200, 777-200LR, 777-300, 777-300ER, 777F

Variable Number Group

WA001 - WA017 1

WA076 - WA080 1

WA086 - WA093 1

WA101 - WA104 1

WA116 - WA119 1

WA131 - WA137 1

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Variable Number Group

WA171 - WA175 1

WA196 - WA198 1

WA206 - WA212 1

WA221 - WA223 1

WA231 - WA232 1

WA241 - WA250 1

WA261 - WA266 1

WA281 - WA283 1

WA301 - WA304 1

WB001 - WB021 1

WB031 - WB046 1

WB051 - WB088 1

WB101 - WB106 1

WB121 - WB125 1

WB131 - WB148 1

WB151 - WB155 1

WB161 - WB177 1

WB181 - WB194 1

WB201 - WB215 1

WB231 - WB247 1

WB271 - WB273 1

WB276 - WB286 1

WB291 - WB302 1

WB306 - WB307 1

WB311 - WB337 1

WB341 - WB342 1

WB366 - WB368 1

WB371 - WB388 1

WB406 1

WB411 - WB413 1

WB416 - WB439 1

WB446 - WB453 1

WB476 1

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Variable Number Group

WB481 - WB484 1

WB501 - WB512 1

WB531 - WB537 1

WB551 - WB554 1

WB591 - WB597 1

WB601 - WB606 1

WB611 - WB622 1

WB631 - WB638 1

WB646 - WB649 1

WC051 - WC073 1

WC101 - WC104 1

WC111 - WC120 1

WC221 - WC224 1

WC241 - WC243 1

WC281 - WC290 1

WC301 - WC308 1

WC361 - WC364 1

WC371 - WC374 1

WC381 - WC395 1

WC441 1

WC446 - WC449 1

WC456 - WC459 1

WC486 - WC493 1

WC506 - WC508 1

WC521 - WC522 1

WC531 - WC536 1

WC546 - WC548 1

WC556 1

WC566 - WC567 1

WC571 - WC574 1

WC581 1

WD001 - WD002 1

WD011 - WD018 1

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Variable Number Group

WD031 - WD036 1

WD046 - WD055 1

WD066 - WD075 1

WD081 - WD089 1

WD091 1

WD096 1

WD101 - WD105 1

WD111 1

WD116 1

WD501 - WD513 1

WD521 - WD541 1

WD546 - WD554 1

WD561 - WD573 1

WD581 - WD599 1

WD606 - WD609 1

WD621 - WD632 1

WD651 - WD665 1

WD671 - WD677 1

WD691 - WD709 1

WD741 - WD752 1

WD761 - WD771 1

WD786 - WD788 1

WD796 - WD819 1

WD826 - WD837 1

WD846 - WD867 1

WD871 - WD886 1

WD911 - WD915 1

WD921 - WD922 1

WD936 - WD939 1

WD946 - WD953 1

WD966 - WD970 1

WD981 - WD982 1

WD986 - WD987 1

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Variable Number Group

WD996 1

WE001 - WE004 1

WE011 - WE012 1

WE021 - WE026 1

WE031 - WE034 1

WE051 - WE054 1

WE071 1

WE081 - WE083 1

WE091 1

WE126 - WE137 1

WE151 - WE153 1

WE176 - WE177 1

WE186 - WE187 1

WE216 - WE217 1

WF001 - WF004 1

WF016 - WF020 1

WF031 - WF033 1

WF046 - WF058 1

WF075 - WF077 1

WF081 - WF088 1

WF096 - WF101 1

WF106 - WF107 1

WF111 - WF113 1

WF121 - WF123 1

WF131 1

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

Model Zone

777-200, 777-200LR, 777-300, 211, 212

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.

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ALERT ALERT
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.

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.50 0.50

Figure 1 1 0.75 0.75

Figure 2 2 4.50 2.25

Figure 3 1 1.00 1.00

Figure 4 1 1.50 1.50

Figure 5 2 2.00 1.00

Test 1 0.50 0.50

Figure 6 2 6.50 3.25

Close Access 1 0.50 0.50

TOTAL FOR EACH AIRPLANE 17.75 11.25

H. Weight and Balance Changes

Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

777-200/-200LR, + 0.2 lb + 48.0 lb-in

777F

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Change in Moment

(Pound-Inches)

Change in Weight

Airplane (Pounds)

777-300/-300ER + 0.2 lb + 3.9 lb-in

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:

Drawing Number Title

208W4100 Tubing Installation Right Side Cab STA 126.5 - 246

208W4101 Tubing Installation Left Side Cab STA 126.5 - 246

208W4103 Tubing Installation Flight Deck Partition STA 246

232W1403 Lining Installation - No. 3 Window

232W1405 Console Installation - Forward

232W1406 Console Installation - Side

232W1411 Lining Installation - Right Side Aft

232W1414 Molding Installation - Aft Lining

232W4302 Console Installation - Observer

232W4305 Stowage Installation - Right Side

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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BOEING SERVICE BULLETIN 777-35A0027

ALERT ALERT
K. Publications Affected

1. Publications:

Publication Chapter-Section

777 Illustrated Parts Catalog 35-11

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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ALERT ALERT

BLANK PAGE
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 Service Bulletin (US

Dollars)

ROLT as of the

original issue

date of this Service Bulletin (Calendar Days)

Kit Number Name Date QTY

005W3527-1 Top Kit 11/22/2011 1 149 $1066.00

005W3527-1 Top Kit 1/09/2012 66

005W3527-1 Top Kit 1/16/2012 66

005W3527-1 Top Kit 1/23/2012 66

005W3527-1 Top Kit 1/30/2012 66

005W3527-1 Top Kit 2/06/2012 66

005W3527-1 Top Kit 2/13/2012 66

005W3527-1 Top Kit 2/20/2012 66

005W3527-1 Top Kit 2/27/2012 66

005W3527-1 Top Kit 3/05/2012 66

005W3527-1 Top Kit 3/12/2012 66

005W3527-1 Top Kit 3/19/2012 66

005W3527-1 Top Kit 3/26/2012 63

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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ALERT ALERT
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

Top Kit 1 2 3 4 5

005W3527-1 1 1 1 1 1

ALL

KIT 005W3527-1

Notes

Existing Part

Name Number

Figure

New Part Number

1 2 3 4 5

Qty

232U8002-723 3 . . . . SLEEVE (a) (b)

232U8002-731 1 . . . . SLEEVE (a) (b)

57034-33N040220 . 1 1 1 . HOSE ASSY 57034-81220 (a) (c)

57034-33N040320 . . . . 1 HOSE ASSY 57034-81320 (a) (c)

57034-34N040100 . 1 . . . HOSE ASSY 57034-91100 (a) (c)

(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

Part Number QTY Name Notes

P29 - 1 inch wide, - P29 Tape (a)

color optional

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ALERT ALERT
Part Number QTY Name Notes

(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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ALERT ALERT

BLANK PAGE
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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ALERT ALERT
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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ALERT ALERT
FIGURE 1: LOW PRESSURE OXYGEN HOSE SLEEVE AND TAPE INSTALLATION

(SHEET 1 OF 3)

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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 each airplane.

FIGURE 1: LOW PRESSURE OXYGEN HOSE SLEEVE AND TAPE INSTALLATION

(SHEET 2 OF 3)

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ALERT ALERT
Step Task Name Identification Qty More Data

1 Install (New) SLEEVE 232U8002-731 1 (a)

Install on 57034-

33N040320 oxygen

hose.

2 Install (New) SLEEVE 232U8002-723 3 (a)

Install on 57034-

33N040220 oxygen

hoses

3 Apply Tape - - (b)

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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ALERT ALERT
FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS

(SHEET 1 OF 4)

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ALERT ALERT
FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS

(SHEET 2 OF 4)

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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 each airplane.

Step Task Name Identification Qty More Data

Refer to 777 AMM

25-15-03 as an accepted procedure.

(a)

First Officer Forward - -

Console

1 Remove / Keep

Refer to 777 AMM

35-11-18 as an accepted procedure.

Oxygen masks do

not need to be removed.

2 Remove / Keep Stowage Box Assembly - -

Remove Upper Part

only of Side Console

Top. Refer to 777

AMM 25-15-01 as

an accepted procedure.

First Officer Side Con- - -

sole Top

3 Remove / Keep

Refer to 777 AMM

35-00-00 as an accepted procedure.

4 Remove HOSE ASSY 57034-91100 1

Refer to 777 AMM

35-00-00 as an accepted procedure.

5 Install (New) HOSE ASSY 57034-34N040100 1

Loose install First

Officer Side Console

Top. (b)

First Officer Side Con- - -

sole Top

6 Install (Temporary)

Refer to 777 AMM

35-00-00 as an accepted procedure.

7 Remove HOSE ASSY 57034-81220 1

Refer to 777 AMM

35-00-00 as an accepted procedure.

Refer to APPENDIX

A for more information.

8 Install (New) HOSE ASSY 57034-33N040220 1

Do not install

Stowage Box. Insert

Stowage Box and

leave in place. (b)

9 Insert Stowage Box Assembly - -

FIGURE 2: FIRST OFFICER SIDE CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENTS

(SHEET 3 OF 4)

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ALERT ALERT
Step Task Name Identification Qty More Data

(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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ALERT ALERT
FIGURE 3: CAPTAIN OXYGEN STOWAGE BOX LOW PRESSURE OXYGEN HOSE REPLACEMENT

(SHEET 1 OF 3)

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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 each airplane.

FIGURE 3: CAPTAIN OXYGEN STOWAGE BOX LOW PRESSURE OXYGEN HOSE REPLACEMENT

(SHEET 2 OF 3)

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ALERT ALERT
Step Task Name Identification Qty More Data

Refer to 777 AMM

35-11-18 as an accepted procedure.

Oxygen masks do

not need to be removed.

1 Remove / Keep Stowage Box Assembly - -

Refer to 777 AMM

35-00-00 as an accepted procedure.

2 Remove HOSE ASSY 57034-81220 1

Refer to 777 AMM

35-00-00 as an accepted procedure.

Refer to APPENDIX

A for more information.

3 Install (New) HOSE ASSY 57034-33N040220 1

Do not install

Stowage Box. Insert

Stowage Box and

leave in place. (a)

4 Insert Stowage Box Assembly - -

(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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ALERT ALERT
FIGURE 4: FIRST OFFICER STOWAGE CLOSET LOW PRESSURE OXYGEN HOSE REPLACEMENT

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 777-35A0027

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 each airplane.

FIGURE 4: FIRST OFFICER STOWAGE CLOSET LOW PRESSURE OXYGEN HOSE REPLACEMENT

(SHEET 2 OF 3)

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ALERT ALERT
Step Task Name Identification Qty More Data

1 Remove / Keep Close Out Seal - -

2 Remove / Keep Screws - 9

3 Remove / Keep Flight Deck Lining - -

Refer to 777 AMM

35-11-18 as an accepted procedure.

Oxygen masks do

not need to be removed.

4 Remove / Keep Stowage Box Assembly - -

Refer to 777 AMM

35-00-00 as an accepted procedure.

5 Remove HOSE ASSY 57034-81220 1

Refer to 777 AMM

35-00-00 as an accepted procedure.

Refer to APPENDIX

A for more information.

6 Install (New) HOSE ASSY 57034-33N040220 1

Do not install

Stowage Box. Insert

Stowage Box and

leave in place. (a)

7 Insert Stowage Box Assembly - -

(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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ALERT ALERT
FIGURE 5: OBSERVERS CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENT

(SHEET 1 OF 3)

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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 each airplane.

FIGURE 5: OBSERVERS CONSOLE LOW PRESSURE OXYGEN HOSE REPLACEMENT

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 777-35A0027

ALERT ALERT
Step Task Name Identification Qty More Data

Refer to 777 AMM

35-11-18 as an accepted procedure.

Oxygen masks do

not need to be removed.

1 Remove / Keep Stowage Box Assembly - -

(a) (b) (c) Move Observer Console

away from wall to

gain access to oxygen hose. Refer to

777 AMM 25-15-05

as an accepted procedure.

2 Move Observers Console - -

Refer to 777 AMM

35-00-00 as an accepted procedure.

3 Remove HOSE ASSY 57034-81320 1

Refer to 777 AMM

35-00-00 as an accepted procedure.

Refer to APPENDIX

A for more information.

4 Install (New) HOSE ASSY 57034-33N040320 1

Do not install

Stowage Box. Insert

Stowage Box and

leave in place. (d)

5 Insert Stowage Box Assembly - -

(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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ALERT ALERT
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION

(SHEET 1 OF 5)

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ALERT ALERT
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION

(SHEET 2 OF 5)

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ALERT ALERT
FIGURE 6: FLIGHT DECK INTERIOR RESTORATION

(SHEET 3 OF 5)

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BOEING SERVICE BULLETIN 777-35A0027

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 each airplane.

Step Task Name Identification Qty More Data

Install Upper Part of

Side Console Top.

Refer to 777 AMM

25-15-01 as an accepted procedure.

First Officer Side Con- - -

sole Top

1 Install (Kept)

Refer to 777 AMM

25-15-03 as an accepted procedure.

First Officer Forward - -

Console

2 Install (Kept)

FIGURE 6: FLIGHT DECK INTERIOR RESTORATION

(SHEET 4 OF 5)

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ALERT ALERT
Step Task Name Identification Qty More Data

Refer to 777 AMM

25-15-05 as an accepted procedure.

Only insert the

Stowage Box.

3 Install (Kept) Observers Console - -

4 Install (Kept) Flight Deck Lining - -

5 Install (Kept) Screws - 9

6 Install (Kept) Close Out Seal - -

Refer to 777 AMM

35-11-18 as an accepted procedure.

7 Install (Kept) Stowage Box Assembly - 4

FIGURE 6: FLIGHT DECK INTERIOR RESTORATION

(SHEET 5 OF 5)

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ALERT ALERT
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)

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ALERT ALERT