# D

S.B. 8 ---27 ---111 Page 1 of 16 15 Jun 2011 JR 

# 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 INFORMA TION 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

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 2 of 16 15 Jun 2011 JR 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).

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 3 of 16 15 Jun 2011 JR 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

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 4 of 16 15 Jun 2011 JR 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 INFORMA TION A. Parts Required Per Aircraft (1) Modification Kit 8MK4453 ---001 (2) Detailed Kit Content:

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 5 of 16 15 Jun 2011 JR 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

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 6 of 16 15 Jun 2011 JR 3. ACCOMPLISHMENTINSTRUCTIONS 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.

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 7 of 16 15 Jun 2011 JR (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.

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 8 of 16 15 Jun 2011 JR (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.

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 9 of 16 15 Jun 2011 JR (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.

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 10 of 16 15 Jun 2011 JR (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.

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 11 of 16 15 Jun 2011 JR Pilots Pedals Figure 1BOLT NAS1801 ---3D10 WASHER AN960D10L LOCK WIRE MS20995C32

8Z6930 ---061 (Pre MS) 8Z6930 ---053 BOLT NAS1103 ---3 NUT MS21042 ---3 WASHER AN960D10LCONTINUED 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)

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 12 of 16 15 Jun 2011 JR Co ---Pilots Pedals Figure 2FROM 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

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 13 of 16 15 Jun 2011 JR 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

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 14 of 16 15 Jun 2011 JR Bushing Installation Figure 4 BUSHING 82710297 ---101 (one on each lug)

(Pre MS) (Pre MS)

0.310 ± 0.030 2 PLCS

EDGE DISTANCE

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 15 of 16 15 Jun 2011 JR Bushing Installation Figure 5 (Pre MS) (Pre MS)

BUSHING 82710297 ---101 (one on each lug) 2

0.310 ± 0.030 2 PLCS EDGE DISTANCE

### SERVICE BULLETIN 8 ---27 ---111

S.B. 8 ---27 ---111 Page 16 of 16 15 Jun 2011 JR Edge to edge length reference

Figure 6 1Jan 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.comFeb 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 VCompliance VApproval V Manpower V Material VWeight and Balance V Electrical Load VTooling V References V Publications Affected 2. MATERIAL INFORMATION V Kit Content VSpecial Tools/Equipment V Parts to Modify Spares V Consumables V Disposition of Existing Parts VOther
3. ACCOMPLISHMENT INSTRUCTIONS VJob Set ---Up V Procedure V Close---Out VTest 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