D

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SERVICE BULLETIN

Customer

Support

ATA SYSTEM: 2730 NUMBER: 8 ---27 ---111

BOMBARDIER AEROSPACE REGIONAL AIRCRAFT CONSIDER THIS

SERVICE BULLETIN TO BE PARTICULARLY SIGNIFICANT AND

URGES OPERATORS TO PROMPTLY EVALUATE THE CONTENTS

SUBJECT: Flight Controls --- Addition of Bushing in Brake Pedal Bell Crank ---

Rudder Control --- ModSum 8Q113007

1. PLANNING INFORMATION

A. Effectivity

Aircraft Affected:

In ---Service: DHC ---8 Aircraft Models 102, 103, 106, 201, 202, 301, 311,

314 and 315 Serial Numbers 003 thru 672.

NOTE: The instructions in this service bulletin are only applicable to the systems

and parts installed at the time of delivery on the aircraft or as changed by

Bombardier Aerospace Service Bulletin(s). Before you do this bulletin,

examine all STC or equivalent action changes to make sure this bulletin

can be completed.

Spares Affected:

None
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B. Reason

Problem: During maintenance, an operator found that the LH & RH pilot brake pedal

bellcrank had exhibited excessive wear in the tie rod attachment clevis

hole.

Solution: This service bulletin provides instructions to add a steel bushing to the rod

attachment clevis hole, or replace with new bellcrank containing steel

bushing.

C. Description

The procedures in this service bulletin give the instructions to do the tasks that

follow:

--- aircraft is put into standard configuration for maintenance

--- aircraft electrical power is removed

--- the nose landing gear lock is engaged

--- the main landing gear lock pins are installed thru each main gear and main gear

door mechanism

--- pilot & co ---pilot brake pedal bellcranks are inspected

--- pilot & co ---pilots bellcranks are either re ---worked to install steel bushing or

replaced

--- close out.

D. Compliance

Bombardier Inc. highly recommend that ModSum 8Q113007 be incorporated at

the earliest opportunity unless otherwise directed by the operator’s airworthiness

authority.

E. Approval

The technical content of this service bulletin has been approved under the

authority of the Transport Canada Civil Aviation (TCCA) Design Approval

Organization No: DAO #93 ---Q ---02.

This Service Bulletin does not affect Airworthiness Limitations (AWLs) or Damage

Tolerance Inspections (DTIs).
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F. Manpower

The following is the man ---hours required to complete the ACCOMPLISHMENT

INSTRUCTIONS in this service bulletin. The breakdown of man ---hours is shown in

the table that follows:

TASK MAN ---HOURS

Job Set ---Up 0.50

Procedure (Inspection) 1.00

Procedure (Bushing Installation) 4.00

Procedure (Bellcrank Replacement) 16.00

Test / RTS 2.00

Close ---Out 0.50

For any on---site labor assistance, please speak with a Fleet Services representative for

a quote. The Fleet Services group can be contacted via the Q Series Technical Help

Desk by telephone at 416---375---4000 or email at: thd.qseries@aero.bombardier.com

G. Material --- Price and Availability

ModKit 8MK4453 ---001 is available through the Customer Accounts Service Team

at Bombardier Aerospace Regional Aircraft division. Operators should submit a

purchase order specifying aircraft serial number(s) to:

Bombardier Aerospace

Customer Accounts Services Team (Mail Stop N11 ---32)

123 Garratt Blvd.

Toronto

Ontario

Canada M3K ---1Y5

Facsimile: (416) 375 ---3060

Telephone: (416) 375 ---3920

Kit Number Description

8MK4453 ---001 Retrofit Kit ---Bellcrank Assembly --- Pedal Assembly

Rudder Controls
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H. Tooling --- Price and Availability

None

I. Weight and Balance

None

J. Electrical Load Data

Not affected

K. Publications Affected

Dash 8 Illustrated Parts Catalogue PSM 1 ---8 ---4 and ....................

PSM 1 ---82 ---4

PSM 1 ---83 ---4

Modifications Manual PSM 1 ---813 ---12 ...............................

L. References

The initial issue of this service bulletin was prepared to the engineering drawings

and related data that follows:

DRAWING SHEET REV

8MK4453 1 A

8Z6930 1 D

ModSum 8Q113007 Rev. ‘C’

PCA 6753 Revision 0 (for internal reference only)

Transport Canada Airworthiness Directive Pending

2. MATERIAL INFORMATION

A. Parts Required Per Aircraft

(1) Modification Kit 8MK4453 ---001

(2) Detailed Kit Content:
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Quantity Per Kit

---001

Part Number Description Remarks

4 MS24665 ---163 Cotter Pin

4 NAS6603CD13 Bolt

8 82710297 ---101 Bushing

1 8Z6930 Retrofit Bellcrank Assembly Drawing

1 8MK4453 Retrofit Kit Drawing

(3) In addition to the above parts, the following material is required for the

completion of this service bulletin and may be procured as single items from

Bombardier Aerospace Regional Aircraft or purchased directly from industry

sources.

Addresses of manufacturers and suppliers not shown below are listed in either

Maintenance Manual Chapter 20 or in Structural Repair Manual Chapter 51.

Part Number Qty. Per Aircraft Description Remarks

MS20995C32 as required Lockwire

F19 as required Primer --- Type II MIL ---PRF ---23377

B. Parts Required to Modify Spares

None

C. Special Tools and Equipment Required

None

D. Existing Parts Accountability

None
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3. ACCOMPLISHMENT INSTRUCTIONS

A. Job Set ---Up

(1) Placard and select all aircraft electrical power to OFF. Obey all relevant

WARNINGS and CAUTIONS (refer to AMM Chapter 24).

(2) Make sure that lock pins are installed thru each main gear and main gear door

mechanism.

(3) Make sure the nose gear ground lock is engaged.

(4) Remove access panels 121AL and 122AR from the nose fuselage. Refer to

Maintenance Manual Chapter 06 ---40 ---10 (S100/300) and 06 ---40 ---00 (S200).

B. Procedure

(1) Insert rig pins A, B, C and D in the LH and RH rudder output levers and rudder

forward quadrants. Refer to Maintenance Manual Chapter 27 ---20 ---00.

(2) Disconnect control rod assembly 82710795 ---001 or 82710024 ---003 (four

places). Retain hardware, discard cotter pin. Refer to Figure 1.

Part A --- Inspection

(1) Determine length of clevis holes on each bellcrank. If length is less than or equal

to 0.218 inches from edge to edge (see Figure 6 for reference) then crack check

using Liquid Penetrant Inspection (LPI). Refer to ASTM E1417.

(2) If crack is found, replace with new bellcrank (refer to Part C. Bellcrank

Replacement), otherwise rework the bellcrank (refer to Part B Bushing

Installation (In ---Situ)).

(3) If length is greater than 0.218 inches replace with new bellcrank (refer to Part C

Bellcrank Replacement).

Part B --- Bushing Installation (In ---Situ)

(1) Disconnect rod assembly 82710274 ---001 (two places) from bellcranks on pilots

side. Retain hardware, discard cotter pin. Refer to Figure 1.

(2) Disconnect cable assembly 82700570 ---001/ ---003 from bellcranks on co ---pilots

side. Retain hardware, discard cotter pin. Refer to Figure 2.

NOTE: In order to remove the clevis pins from the co ---pilots bellcranks the cable

tension must be released by temporarily moving the brake control

assembly levers on the pilots side forward.
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(3) Open the hole on original center in bellcrank assembly as shown in section

A ---A/B ---B of Figures 4 & 5 using a reamer 0.250 inches diameter with a 0.187

inches pilot.

NOTE: Reamer should not be longer than 2 inches and to be used with an angle

drill.

NOTE: Alternatively, bushing installation may be conducted outside the aircraft.

Follow the applicable instructions in Part C to remove the bellcrank from

the aircraft and to install the reworked bellcrank into aircraft.

NOTE: If original hole is damaged, bellcrank may be re ---used only if hole

enlargement (to the size shown in section A ---A/B ---B) is sufficient to repair

the damage and edge distance as shown in Figure 4 can be maintained.

Otherwise bellcrank requires replacement. Replace with

82710813 ---003/ ---004 and 82710814 ---003/ ---004. For aircraft without

ModSum 8Q101218 installed also use 82710813 ---003/ ---004 and

82710814 ---003/ ---004.

(4) Deburr holes. Make sure edge distance is 0.310± 0.030 inches. Refer to Figures

4 & 5.

(5) Refer to Figures 4 & 5 wet install bushings 82710297 ---101 into bellcrank

assembly using F19 primer. Refer to AMM 20 ---12 ---04 for applicable instruction.

(6) Re ---identify bellcrank assembly 82710813 ---001/ ---002 as 8Z6930 ---051/ ---053

and 82710814 ---001/ ---002 as 8Z6930 ---055/ ---057. Refer to Maintenance Manual

Chapter 20 ---15 ---04.

(7) Re ---identify bellcrank assembly 82710022 ---001/ ---002 as 8Z6930 ---059/ ---061

and 82710029 ---001/ ---002 as 8Z6930 ---063/ ---065 for aircraft without ModSum

8Q101218 installed. Refer to Maintenance Manual Chapter 20 ---15 ---04.

(8) Connect control rod assembly 82710795 ---001 or 82710024 ---003 (four places) to

reworked bellcranks using kept hardware and new bolt NAS6603CD13 and new

cotter pin MS24665 ---163. Refer to Figure 1. If bolt doesn’t fit, ream bushing to

0.190/0.192 inches diameter.

(9) Connect rod assembly 82710274 ---001 (two places) to reworked bellcranks on

pilots side using kept hardware and new cotter pin MS24665 ---153. Refer to

Figure 1.

(10) Connect cable assembly 82700570 ---001/ ---003 to reworked bellcranks on

co ---pilots side using kept hardware and new cotter pin MS24665 ---153. Refer to

Figure 2.

Part C --- Bellcrank Replacement

(1) On the flight compartment floor, remove and retain all the screws securing the

rudder pedal cover to the floor. Leave cover in place.
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(2) Disconnect rod assembly 82710274 ---001 (two places) from bellcranks on pilots

side. Retain hardware, discard cotter pin. Refer to Figure 1.

(3) Disconnect cable assembly 82700570 ---001/ ---003 from bellcranks on co ---pilots

side. Retain hardware, discard cotter pin. Refer to Figure 2.

(4) Disconnect rudder force sensor 9000934 ---1 or rod assembly 82710028 ---003

(four places) from the rudder control pedal assembly. Retain hardware, discard

cotter pin. Refer to Figure 1.

(5) Remove microswitch support bracket 82710812. Retain hardware and shim if

present. Be careful not to damage microswitches. Refer to Figure 3.

(6) Index mark rudder control pivot assembly mounting flange and fitting on both

sides.

(7) Remove pivot assembly fitting 82710021---101. Retain hardware. Refer to Figure 2.

(8) Remove and retain hardware from the pivot assembly mounting flange. Refer to

Figure 2.

(9) While holding the pivot tube assembly gently twist the assembly and slightly

move it aft until it clears the rudder pedal assembly mounting brackets.

(10) Rotate the pivot tube mounting flange in a clockwise and anti ---clockwise

direction while moving towards the inboard until tube as moved enough to

remove the bellcrank.

NOTE: As you move the pivot tube inboard be sure to support the teflon spacers

and bushings.

(11) Remove affected bellcrank and replace with a new bellcrank containing steel

bushing.

(12) Rotate the pivot tube mounting flange in a clockwise and anti ---clockwise

direction while moving towards the outboard until its fully through.

(13) While holding the pivot tube assembly gently twist the assembly and slightly

move it forward until it positions itself on the rudder pedal assembly mounting

brackets.

(14) Install pivot assembly fitting 82710021 ---101 using kept hardware. Refer to

Figure 2.

(15) Secure pivot assembly mounting flange to the rudder pedal assembly mounting

brackets using kept hardware.

(16) Install microswitch support bracket 82710812 and shim 82710602 ---953, if

originally present, using kept hardware. Refer to Figure 3.

(17) Connect rudder force sensor 9000934 ---1 or rod assembly 82710028 ---003 (four

places) to the rudder control pedal assembly using kept hardware and new

cotter pin MS24665 ---153. Refer to Figures 1 & 2.
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(18) Connect cable assembly 82700570 ---001/ ---003 to the bellcranks on co ---pilots

side using kept hardware and new cotter pin MS24665 ---163. Refer to Figure 2.

(19) Connect rod assembly 82710274 ---001 (two places) to the bellcranks on pilots

side using kept hardware and new cotter pin MS24665 ---163. Refer to Figure 1.

(20) On the flight compartment floor secure the rudder pedal cover to the floor using

kept hardware.

(21) Connect control rod assembly 82710795 ---001 or 82710024 ---003 (four places) to

bellcranks using kept hardware and new bolt NAS6603CD13 and new cotter pin

MS24665 ---163. Refer to Figure 1.

(22) Identify the installation as 8Z6930 ---001 & 8Z6930 ---002 and 8Z6930 ---003 &

8Z6930 ---004 for aircraft without ModSum 8Q101218 installed.

Refer to Maintenance Manual Chapter 20 ---15 ---04.

C. Close Out

(1) Do the Return to Service Procedure as follows:

(d) Remove rig pins A, B, C and D.

(e) Move the pedal adjustment mechanism fully forward and operate the

rudder pedals forward and aft.

Check for full and free movement of the rudder pedals.

For aircraft equipped with force sensors 9000934 ---1, check for clearance

between the sensor harness and the adjacent components.

Inspect for clearance as follows:

(f) Minimum clearance of 0.12 inches (3.05 mm) between the harness and

surrounding components.

(g) Minimum clearance of 0.375 inches (9.53 mm) between the force sensor

and surrounding components except the fitting assembly and the aft rod

end bearing of the force sensor.

(h) Move the pedal adjustment mechanism fully aft and operate the rudder

pedals forward and aft.

Check for full and free movement of the rudder pedals.

For aircraft equipped with force sensors 9000934 ---1, check for clearance

between the sensor harness and the adjacent components.

Inspect for clearance as follows:

1 Minimum clearance of 0.12 inches (3.05 mm) between the harness

and surrounding components.

2 Minimum clearance of 0.375 inches (9.53 mm) between the force

sensor and surrounding components except the fitting assembly and

the aft rod end bearing of the force sensor.
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(i) Apply full pilot brake travel to each pedal for a minimum of 25 cycles. Make

sure the system has full and free movement.

(j) Apply full co ---pilot brake travel to each pedal for a minimum of 25 cycles.

Make sure the system has full and free movement.

NOTE: Make sure the brake linkages go back to their initial position after each

brake application. The co ---pilot brake lever will touch the structural stop.

(k) Check and if necessary, adjust the brake position switch. Refer to

Maintenance Manual Task 27 ---20 ---03 ---400 ---802 (Series 200) or Chapter

27 ---20 ---03 Section 4 (Series 300).

(2) Remove all tools and equipment from the work area.

(3) Install access panels 121AL and 122AR to the nose fuselage. Refer to

Maintenance Manual Chapter 06 ---40 ---10 (Series 100/300) or 06 ---40 ---00 (Series

200).

(4) On incorporation of this ModSum, make an entry that conforms to local

regulatory requirements in the applicable logbook(s). Enter component serial

numbers if applicable. Enter this ModSum number only after complete and

functional incorporation of all work defined in this service bulletin.
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Pilots Pedals

Figure 1

BOLT NAS1801 ---3D10

WASHER AN960D10L

LOCK WIRE MS20995C32

8Z6930 ---061 (Pre MS)

8Z6930 ---053

BOLT NAS1103 ---3

NUT MS21042 ---3

WASHER AN960D10L

CONTINUED ON FIGURE 2

8Z6930 ---059

(Pre MS)

8Z6930 ---051

BOLT NAS1303 ---7D

NUT MS14144L3

WASHER AN960D10L

COTTER PIN

MS24665 ---163

BOLT NAS1103 ---3

NUT MS21042 ---3

WASHER AN960D10L

RUDDER PEDAL ASSEMBLY (TYP)

MOUNTING BRACKET

ROD ASSEMBLY

82710274 ---001

RUDDER FORCE SENSOR

9000934 ---1 (TYP)

OR

ROD ASSEMBLY

82710028 ---003 (TYP)

CONTROL ROD ASSEMBLY (TYP)

82710795 ---001 or 82710024 ---003

(TYP)
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Co ---Pilots Pedals

Figure 2

FROM FIGURE 1

BOLT NAS1801 ---3D10

WASHER AN960D10L

LOCK WIRE MS20995C32

8Z6930 ---063 (Pre MS)

8Z6930 ---055

BOLT NAS1303 ---3

NUT MS21042 ---3

WASHER AN960D10L

8Z6930 ---065

(Pre MS)

8Z6930 ---057

PIN MS20392 ---2C11

COTTER PIN MS24665 ---153

WASHER AN960D10L

BOLT NAS1303 ---3

NUT MS21042 ---3

WASHER AN960D10L

CABLE ASSEMBLY

82700570 ---001

CABLE ASSEMBLY

82700570 ---003

PIVOT ASSEMBLY

MOUNTING FLANGE (TYP)

PIVOT ASSEMBLY

FITTING (TYP)

82710021 ---101
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Detail C and D

Figure 3

BOLT

NAS6603CD13

NUT

MS14144L3

WASHER

AN960D10L

COTTER PIN

MS24665 ---163

NOTE: Tighten nut to ensure positive

clamp ---up of bearing inner race.

8Z6930 ---059 (Pre MS)

8Z6930 ---051

8Z6930 ---063 (Pre MS)

8Z6930 ---055

8Z6930 ---061 (Pre MS)

8Z6930 ---053

8Z6930 ---065 (Pre MS)

8Z6930 ---057

MICROSWITCH

SUPPORT BRACKET

82710812

ROD ASSEMBLY

P/N 82710795 ---001 or P/N 82710024 ---003
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Bushing Installation

Figure 4

BUSHING

82710297 ---101

(one on each lug)

(Pre MS)

(Pre MS)

0.310 ± 0.030 2 PLCS

EDGE DISTANCE
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Bushing Installation

Figure 5

(Pre MS)

(Pre MS)

BUSHING

82710297 ---101

(one on each lug)

2

0.310 ± 0.030 2 PLCS

EDGE DISTANCE
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Edge to edge length reference

Figure 6

1
Jan 2009

SERVICE BULLETIN (SB) --- RECORD OF INCORPORATION

--- Q SERIES DASH 8 AIRCRAFT

To: CMDB Focal

Facsimile: (1) 416 375 4538

E --mail: cmdb.requests@aero.bombardier.com

From:

Company:

Phone: Extn:

Facsimile: Date:

E --mail:

The data that you provide below will help us record the incorporation of this ModSum

and the aircraft effectivity in the maintenance manual.

Operator: Service Bulletin: __________________ Revision: _________

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Aircraft Serial Number: Model Number: Date Bulletin Completed:

Fax this sheet to (1) 416 375 4538 or Email PDF to:

cmdb.requests@aero.bombardier.com
Feb 2009

SERVICE BULLETIN (SB) --- COMMENT SHEET --- Q SERIES DASH 8 AIRCRAFT

To: SB Focal (Toronto), Bombardier Aerospace Commercial Aircraft

Phone: (1) 416 375 4078 Facsimile: (1) 416 375 4538

E --mail: syed.rizvi@aero.bombardier.com

From:

Company:

Phone: Extn:

Facsimile: Date:

E --mail:

Select appropriate box(es) and add comments or suggestions you would like us to know

that may enhance the quality of our service bulletins.

Service Bulletin: Revision: ModSum:

1. PLANNING INFORMATION

V Effectivity V Reason V Description V Compliance

V Approval V Manpower V Material V Weight and Balance

V Electrical Load V Tooling V References V Publications Affected

2. MATERIAL INFORMATION

V Kit Content V Special Tools/Equipment V Parts to Modify Spares

V Consumables V Disposition of Existing Parts V Other

3. ACCOMPLISHMENT INSTRUCTIONS

V Job Set ---Up V Procedure V Close---Out V Test

V Illustration(s) V Other

4. COMMENTS, REMARKS, SUGGESTIONS

Fax this sheet to (1) 416 375 4538 or Email PDF to:

syed.rizvi@aero.bombardier.com