Revision ‘B’ 13 Mar 2013

DHC-8 (DASH 8)

SERVICE BULLETIN 8-54-39

Nacelles - Lower Longeron, Left and Right Hand Side - Special

Inspection and Rectification - ModSum 8Q113006

This page transmits Revision ‘B’ of Service Bulletin 8-54-39, pages 1 thru 32,

dated 13 Mar 2013.

This service bulletin is re-issued in its entirety for the reasons that follow:

- the In-Service part of the Effectivity section is revised to change Pre-Mod

8/1593 longeron to Pre-Mod 8/1702 longeron without Mod 8/1593 incorporated

- the Production part of the Effectivity section is added

- the Problem part of the Reason section is revised to change Pre-Mod 8/1593

longeron to Pre-Mod 8/1702 longeron without Mod 8/1593 incorporated

- the Manpower section is revised to change the estimated manhours from

18/21 to 17/21

- the References section is revised to convey the latest revision of the service

bulletin and engineering documentation

- the Detailed Kit Content of the Parts Required Per Aircraft section is revised

to change the Part Number of Cotter Pin from MS25665-306 to MS24665-306

- the EFFECTIVITY ofAppendix Ais revised to change Pre-Mod 8/1593 longeron

to Pre-Mod 8/1702 longeron without Mod 8/1593 incorporated.

The Compliance in the previous issue(s) of this service bulletin is not

affected by this revision. No additional rework to the aircraft is introduced by

this revision.

Remove the previous revision of Service Bulletin 8-54-39 and replace with

attached.
Previous issues of Service Bulletin 8-54-39:

Initial issue - Pages 1 thru 32 dated 14 Mar 2012

Revision ‘A’ - Pages 1 thru 32 dated 02 Aug 2012

1
D

S.B. 8-54-39

Page 1 of 32

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NB

Revision ‘B’ 13 Mar 2013

SERVICE BULLETIN

Customer

Support

BOMBARDIER AEROSPACE REGIONAL AIRCRAFT CONSIDER THIS

SERVICE BULLETIN TO BE PARTICULARLY SIGNIFICANT AND

URGES OPERATORS TO PROMPTLY EVALUATE THE CONTENTS

ATA SYSTEM: 5410 NUMBER: 8-54-39

SUBJECT: Nacelles - Lower Longeron, Left and Right Hand Side - Special

Inspection and Rectification - ModSum 8Q113006

1. PLANNING INFORMATION

A. Effectivity

Aircraft Affected:

In-Service: DHC-8 Aircraft Models 102 & 103 and Models 102 and 103

aircraft that have been converted to Models 106 per Service

Bulletins 8-92-07 or 8-92-08, Serial Numbers 003 to 287 with

Pre-Mod 8/1702 longeron installed without Mod 8/1593

incorporated.

Production: ModSum 8/1702 has been installed before delivery on

applicable DHC-8 Aircraft at Serial Numbers 288 and

subsequent.

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.
SERVICE BULLETIN 8-54-39

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Page 2 of 32

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NB

Revision ‘B’ 13 Mar 2013

Spares Affected:

None

B. Reason

Problem: An operator on a routine maintenance check of a Q100 with Pre-Mod

8/1702 longeron installed without Mod 8/1593 incorporated has reported

a cracked nacelle longeron at the drain holes.

Cause: Possible scoring in bore from installation of tooling bolts.

Solution: This service bulletin gives the instructions to do a detailed visual inspection

(DVI), Bolt Hole Eddy Current (BHEC) test of each longeron p/n 85410309

(qty. 2 per nacelle, inboard and outboard side). If any longeron is

determined to be cracked or the BHEC indicates a high amplitude, a report

will be forwarded to Bombardier Aerospace (Toronto) for action and

disposition. Any indication of a crack is not permitted and must be

addressed / rectified before next flight.

C. Description

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

follow:

- aircraft electrical power is removed

- the nose landing gear lock is engaged

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

gear door mechanism

- workstands or ladders are set in position and electrically grounded at rear spar

adjacent each nacelle

- access panels are opened to gain access to each attachment fitting (lower, left and

right side in each nacelle)

- the Main Gear Retraction Actuator (MGRA) is removed

- each test location (inboard and outboard) is prepared (cleaned) for inspection

- a DVI and/or a BHEC test is completed (Part A)

- all test results are recorded and forward to BA for evaluation

- any indication of a crack is not permitted and must be addressed / rectified. Contact

BA for disposition before next flight

- the new longerons are bench jigged in the removed lower structure and pilot-drilled

undersize

NOTE: The new longerons are supplied blank except for drain holes and bolt

holes.
SERVICE BULLETIN 8-54-39

S.B. 8-54-39

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NB

Revision ‘B’ 13 Mar 2013

- the new longeron and structure are temporarily installed; the longeron is drilled full

size

- the structure and longeron are removed and deburred. The full sized holes are cold

worked for new longerons, or longerons with no crack indications and less than 40K

FC

- the longeron is installed, shimmed and riveted into position

- the items in each nacelle removed for rework are installed

- the main landing gear and doors are installed

- the lower cowlings are installed

- functional checks are carried out to the disturbed systems

- the landing gear retraction actuator is re-installed

- the landing gear is function tested as per AMM

- the aircraft is lowered from jacks

- close out.

D. Compliance

Bombardier Inc. highly recommends that operators inspect their aircraft to

determine the condition of each drain hole in lower nacelle longeron (LH and RH)

as follows:

1. Initial Inspection - Detailed Visual Inspection (DVI) or Bolt Hole Eddy Current

(BHEC) Test:

(a) For Models 102/103 Serial Numbers 003-287 with less than 35,000 flight

cycles or equal, within 5,000 flight cycles or no later than 36,000 flight cycles

Serial Numbers 003-287 with more than 35,000 flight cycles, within 1,000 flight

cycles

(b) For aircraft converted to Model 106 per SB 8-92-07 or 8-92-08 Pre-Mod 8/1641

within 500 flight cycles

(c) For aircraft converted to Model 106 per SB 8-92-07 or 8-92-08 Post-Mod

8/1641 within 5000 flight cycles

2. Repeat Inspection - Bolt Hole Eddy Current (BHEC) Test:

(a) For Models 102 & 103, a repeat inspection is required every 2,500 flight cycles

after initial inspection until longeron is reworked, as applicable, or replaced.
SERVICE BULLETIN 8-54-39

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NB

Revision ‘B’ 13 Mar 2013

(b) For aircraft converted to Model 106 per SB 8-92-07 or 8-92-08, repeat

inspection of 1,854 cycles until longeron is reworked, as applicable, or

replaced.

A Transport Canada Airworthiness Directive Pending.

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).

F. Manpower

PART A - LOWER LONGERON - Detailed Visual Inspection (DVI) or Bolt Hole

Eddy Current (BHEC) Inspection

It will take an estimated 17/21 manhours to complete PART A of the

ACCOMPLISHMENT instructions in this service bulletin. The breakdown of

manhours is shown in the table that follows:

TASK MAN-HOURS

Job Set-Up 1.00/** 3.00

Procedure in Part A ** 10.00

Test / RTS * 5.00

or

*** 1.00

Close-Out 2.00

* Per Nacelle for NDT testing only

** Per Nacelle for Main Gear Retraction Actuator Removal and

installation

*** Per Nacelle for DVI inspection only
SERVICE BULLETIN 8-54-39

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Page 5 of 32

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NB

Revision ‘B’ 13 Mar 2013

PART B - LOWER LONGERON - Removal and Replacement

It will take an estimated 100 man-hours to complete PART B of the

ACCOMPLISHMENT instructions in this service bulletin. The breakdown of

man-hours is shown in the table that follows:

TASK MAN-HOURS

Procedure in Part

B

94.00

Test / RTS 3.00

Close-Out 3.00

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

All costs to incorporate this modification are the responsibility of the Operator.

G. Material - Price and Availability

ModKit 8MK4670-001 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

8MK4670-001 Retrofit Kit - Nacelle, Lower Longeron

Replacement
SERVICE BULLETIN 8-54-39

S.B. 8-54-39

Page 6 of 32

14 Mar 2012

NB

Revision ‘B’ 13 Mar 2013

The part(s) detailed in Paragraph(s) 2.A. may be obtained from any Bombardier

Aerospace Regional Aircraft authorized parts source. The price and availability will

be quoted at the time of order.

H. Tooling - Price and Availability

None

I. Weight and Balance

None

J. Electrical Load Data

Not affected

K. Publications Affected

Maintenance Manual PSM 1-8-2 ................................

Modifications Manual PSM 1-8123-12 ...............................

L. References

Revision ‘B’ of this service bulletin was prepared to the engineering drawings and

related data that follows:

DRAWING SHEET REV

8MK4670 1 A

8Z9324 1 A

8Z9324 2 --

PSM 1-8-2, Maintenance Manual

PSM 1-8-3, Structural Repair Manual

PSM 1-8-7A, Nondestructive Testing Manual

ModSum 8Q113006 Rev. ‘B’

PCA 06503 Revision 0 (for internal reference only)

Transport Canada Airworthiness Directive pending
SERVICE BULLETIN 8-54-39

S.B. 8-54-39

Page 7 of 32

14 Mar 2012

NB

Revision ‘B’ 13 Mar 2013

2. MATERIAL INFORMATION

A. Parts Required Per Aircraft

(1) Modification Kit 8MK4670-001

(2) Detailed Kit Content:

Quantity Per Kit

-001

Part Number Description Remarks

100 MS20615-4M5 Rivet Material - Monel

30 MS20615-4M4 Rivet Material - Monel

8 M7885/8-4-03 Rivet, Blind Material - Monel

12 M7885/8-4-02 Rivet, Blind Material - Monel

15 NAS9303E-5-04 Rivet, Blind

15 NAS9303E-5-03 Rivet, Blind

15 NAS9303E-5-02 Rivet, Blind

10 M7885/6-5-03 Rivet, Blind

10 B0205018AD5-8S Rivet

450 B0205018AD5-7S Rivet

30 B0205018AD5-6S Rivet

140 B0205018AD5-5S Rivet

70 B0205018AD4-4S Rivet

4 B0205017AD3-5S Rivet

10 B0205016AD6-8S Rivet

40 B0205016AD5-8S Rivet

50 B0205016AD5-7S Rivet

220 B0205016AD5-6S Rivet

130 B0205016AD5-5S Rivet

6 B0205016AD4-5S Rivet

2 B0204033-3-8 Anchor Nut

1 MS21047L3 Anchor Nut

6 MS24665-306 Cotter Pin

4 85411406-101 Bushing

4 CSP343-299 Packer, Full

Laminations
SERVICE BULLETIN 8-54-39

S.B. 8-54-39

Page 8 of 32

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NB

Revision ‘B’ 13 Mar 2013

Quantity Per Kit

-001

Part Number Description Remarks

4 CSP343-298 Packer, Full

Laminations

4 PLI-8-19.6 Washer Assembly SPS Technologies

4 MS20002C6 Washer,

Countersunk

8 MS20002-6 Washer

4 DSC97-6 Nut

4 MS21250-06080 Bolt

4 81811-820 Nut SPS Technologies

4 81812-8-102 Bolt SPS Technologies

1 85410309-109 Longeron Right Hand side of

Right Nacelle

See NOTE below

1 85410309-107 Longeron Right Hand side of

Left Nacelle

See NOTE below

2 85410309-111 Longeron Left hand side of

both Nacelles

See NOTE below

1 8MK4670-001 Retrofit Kit -

Nacelle, Lower

Longeron

Replacement

1 8Z9324-001 Retrofit - Nacelle,

Lower Longeron

Replacement

Drawing

NOTE: Longerons are to be supplied blank except for bolt holes and drain holes.
SERVICE BULLETIN 8-54-39

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Page 9 of 32

14 Mar 2012

NB

Revision ‘B’ 13 Mar 2013

(3) In addition to the above part(s), the following material(s) are 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

DHMS S3.01 1/2 Quart Temperature

Resistant, Integral

Fuel Tanks, High

Adhesion

PR 1776M B2,

SAE AMS 3281

Commercials Names:

PR 1422B2 or B1/2

PR 1776M

PR 1776M B1/2

PR 1776M B2

DHMS S3.06 1/2 Quart Type I Class C

Corrosion

Inhibiting Sealant

P/S 870C-80

MIL-PRF-81733

Part A

Part B

F13 (Grade 2) 3 oz. Corrosion

Preventive, Grade

2 Soft Film

MIL-PRF-16173

Grade 2,

Commercials Names:

Tectyl 502C,

Petrotect 2

DHMS SC4.01

F19 (TYPE 2)

1 ounce Chromate Epoxy

Primer

MIL-P-23377

MIL-C-5541 1 ounce Chromate

Conversion

Coating

Commercials Names:

Alocrom 1200,

Alodine 600

Alodine 1200

Alodine 1200S

Alodine 1201

Touch-N-Prep

Coatings:

Alodine 1132 Maker

Turcoat Accelagold

Alocrom 1000
SERVICE BULLETIN 8-54-39

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NB

Revision ‘B’ 13 Mar 2013

Part Number Remarks Qty. Per Aircraft Description

DHMS C4.04

Type 4, Class

A Grade A

F24 Finish

Code

1/2 Quart Enamel,

Polyurethane, for

Aircraft Exterior

Paint System, F24

MIL-PRF-85285

Commercials Names:

Enamel, Base 800

Series, Catalyst 91C0

Primer, Base

515x349, Catalyst

910x533

Enamel, Base 6600

Series Primer, Base

4500-PB-60X,

Catalyst 4500-C-60X

Primer, Base 4251

P0501, Catalyst

420C0078, Solvent

SB 41E and SB 43

Enamel, Base 620H,

Catalyst 620C,

Reducer SB 61

Primer, Base 4251

P0501, Catalyst

420C0078, Solvent

SB 41E and SB 43

A sealant conforming to DHMS S3.01 and S3.06 is available from:

DHMS S3.01 and S3.06 is available from:

PRC -DeSoto International

11601 United Street

Mojave, CA 93501

www.ppgaerospace.com

or

PRC-Desoto Canada Inc.

5676 Timberlea Blvd,

Mississauga, Ontario

L4W 4M6 Canada

Telephone: 905 629 9790

Telephone: 1-800-aeromix [237-6649] (North America)

Facsimile: 905 629 7009

www.ppgaerospace.com
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B. Parts Required to Modify Spares

None

C. Special Tools and Equipment Required

None

D. Existing Parts Accountability

None

3. ACCOMPLISHMENT INSTRUCTIONS

A. Job Set-Up

WARNING: MAKE SURE THAT ALL HYDRAULIC AND ELECTRICAL POWER IS

OFF. MAKE SURE THAT LOCKPINS ARE INSTALLED IN THE DOOR

MECHANISMS AND THE MAIN LANDING GEAR BEFORE YOU DO

MAINTENANCE IN OR AROUND THE MAIN GEAR WHEEL. THE DOOR

MECHANISMS CAN ACCIDENTLY CLOSE, THE LANDING GEAR CAN

ACCIDENTLY RETRACT AND CONTROL SURFACES COULD MOVE.

INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT CAN

OCCUR.

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

WARNINGS and CAUTIONS. Refer to applicable instruction in AMM Chapters 12

and 24.

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

door mechanism.

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

(4) Make sure that the hydraulic system is de-pressurized (refer to applicable

instructions in AMM Chapter 12-00-03).

(5) Install safety devices and/or warning signs on the landing gear controls and the

external hydraulic connection.

(6) Set up the work platforms or ladders as required to gain access to the lower

longeron (left and right hand side). Make sure the ladder or workstand is

electrically grounded.

(7) Remove the main landing gear retraction actuator (refer to applicable

instructions in AMM Chapter 32-30-11).
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B. Procedure

Part A1: Detailed Visual Inspection (DVI) of Longeron Drain Holes

NOTE: Either Detailed Visual Inspection (DVI) or Bolt Hole Eddy Current (BHEC)

Inspection may be performed at Initial Inspection.

(1) Locate the drain holes in each lower longeron inside the No.1 and No.2 nacelle

(Zone 419 and 429). Refer to Figure 1 Sheet 2 of Appendix A for drain hole

locations.

(2) Remove all debris and unwanted materials from each surface area before

conducting the inspection. Refer to applicable instruction in AMM Chapter

51-27-01.

(3) Using an inspection light, visually inspect around the edge of each drain hole in

each longeron for cracks. Record the results.

Part A2: Special Inspection of Lower Longeron - Bolt Hole Eddy Current (BHEC)

Inspection

(1) Locate each lower longeron inside the No. 1 and No. 2 nacelle (Zone 419 and

429).

(2) Remove all debris and unwanted materials from each surface area before

conducting the inspection. Refer to applicable instruction in AMM Chapter

51-27-01.

(3) Do the Nondestructive Testing Procedure as per Appendix A, that follows at the

end of this service bulletin.

Part A3: Disposition for Inspection Results

(1) If no cracks are found and aircraft has less than 40,000 flight cycles or equal:

(a) BHEC is done at subsequent Repeat Inspections until cold working of drain

holes is accomplished as per SB 8-54-23 (Mod 8/1593).

Repeat inspection for Model 102/103 is 2,500 flights.

Repeat inspection for Model 102/103 converted to Model 106 is 1,854 flights.

(b) Cold working of drain holes to be incorporated no later than 40, 000 flight

cycles. BHEC must be done before cold working of drain holes.

(c) Proceed to Close-Out section.
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(2) If no cracks are found and aircraft has more than 40,000 flight cycles.

(a) BHEC is done at subsequent Repeat Inspections until Longeron is replaced.

Repeat inspection for Model 102/103 is 2,500 flights; Repeat inspection for

Model 102/103 converted to Model 106 is 1,854 flights.

(b) Proceed to Close-Out section.

(3) If indications of cracks are found, before next flight, either replace longeron or

contact the ‘‘Toronto Help Desk at telephone number (416) 375-4000 or

facsimile (416) 375-4539’’ or E-mail: thd.qseries@aero.bombardier.com for a

approved repair disposition.

Part B1: Rectification - Removal and Replacement of Lower Longeron (Both

Nacelles)

NOTE: Preparation, retrofit and installation is similar but may vary between each

nacelle and each aircraft.

NOTE: Part B of this service bulletin replaces lower longerons and attachment

hardware (Pre-Mod 8/1702 configuration only).

CAUTION: WHENEVER A PIPELINE IS DISCONNECTED OR REMOVED, A

BLANKING CAP IS TO BE INSTALLED TO PREVENT THE

INTRODUCTION OF FOREIGN MATTER.

(1) Defuel aircraft (refer to applicable instructions in AMM Chapter 28-25-00).

(2) Open hinged door labeled LANDING GEAR ALTERNATE RELEASE located in

flight compartment ceiling.

WARNING: BEFORE OPERATING MAIN GEAR ALTERNATE RELEASE HANDLE,

ENSURE AREA AROUND REAR AND CENTER DOOR IS CLEAR OF

PERSONNEL AND GROUND EQUIPMENT.

(3) Pull main landing gear (MLG) alternate release handle in flight compartment roof

to first detent to open rear and center doors. Install door lock pins in both

nacelles.

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

(5) Remove the forward MLG doors and ALL cowl doors (refer to applicable

instructions in AMM Chapter 32-10-21). Disconnect grounding wires.

(6) Remove all upper and lower and fore and aft side engine cowlings.

(7) Prepare aircraft for lifting on jacks (refer to applicable instructions in AMM

Chapter 07-00-00).

(8) Lift the aircraft on jacks.
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(9) Take engine weight off of the nacelle (refer to applicable instructions in AMM

Chapter 57-30-10).

(10) Remove and retain main landing gear (MLG) hydraulic swivels.

(11) Remove main landing gear (MLG) (refer to applicable instructions in AMM

Chapter 32-10-11). Store gear on portable dolly.

(12) Remove and retain engine condition box and associated wiring. Refer to AMM

Chapter 71-05-00.

(13) On LH wall of nacelle remove and retain following parts:

(a) Engine drain manifold assembly.

(b) All hydraulic tubing along nacelle above longeron, including piping to MLG

swivels.

(14) Remove and discard cotter pins, nuts, bolts and washers securing engine lower

support struts to MLG frames and outer hole of lower longerons.

(15) Remove and discard nuts, bolts and washers securing inner hole of lower

longerons to MLG frames.

NOTE: Existing bolts can be used as slave bolts.

Part B2: Disassembly and Removal of Lower Structure 85410014 (Refer to

Drawing 8Z9324 Sheets 1 and 2)

(1) Refer to sheet 1, Detail A, zone 11B thru 11E (Detail A). Drill and remove forward

row of rivets securing splice straps to lower center nacelle and aft structure at

each side of nacelle. Leave straps intact on aft structure. Install skin grippers to

structure and nacelle.

NOTE: Refer to applicable instructions in AMM Chapter 51-40-00 for

recommended practices for drilling, deburring and fastener installation

procedures.

(2) Remove and retain the drain channels.

(3) Refer to sheet 2, View on Arrow B, zones 20A thru 20H (View on Arrow B). Drill

and remove rivets on horizontal firewall in area of oil cooler box. Install skin

grippers.

(4) Refer to sheet 2, arrows C and D. Drill and remove rivets securing gussets and

brackets onto lower longerons. Retain gussets.
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(5) Remove and retain door actuator stop arm 85410512 and angles 85411159 /

85411235 from LH side of nacelle at rear of lower longeron (refer to sheet 2,

View on Arrow B, zone 19H).

(6) Refer to sheet 1, Detail A, zones 11E thru 19E (Detail A). Drill and remove rivets

from lower longeron skin flanges and from bottom rivets at cleats securing

frames to longerons.

NOTE: Cleats remain attached to frames.

(7) Drill and remove rivets securing MLG uplock diagonal brace to LH and RH lower

longerons. Leave cleats and diagonal member attached to adjacent upper

frames.

(8) Refer to sheet 2, View on Arrow B, zones 22A and 22H. Drill and remove rear

rivets from angles 85410569 where secured onto upper skin.

WARNING: LOWER STRUCTURE IS FLEXIBLE AND BULKY. THE ASSISTANCE OF

ADDITIONAL OPERATORS IS REQUIRED TO AVOID POSSIBLE

PERSONAL INJURY DURING REMOVAL.

(9) Support weight of lower center structure, remove skin grippers and carefully

remove structure from nacelle.

NOTE: Lower longerons remain attached to lower center section by skin

grippers.

(10) Remove lower longerons from upper center structure; remove and discard

packers. Retain longerons for transfer of holes onto templates.

(11) Temporarily, move and place the lower structure 85410014 with lower longerons

to suitable fixture to gain access for longeron re-installation.

Part B3: Preparation of New Lower Longerons and Lower Structure 85410014

(Refer to Drawing 8Z9324 Sheet 2)

(1) Prepare four suitably sized templates of a minimum thickness of 16 Standard

Wire Gage aluminum alloy (0.063 inch) to accept lower longerons.

CAUTION: DRILLING OF THE FRAME HOLES INTO TEMPLATES FROM THE

REMOVED LONGERONS AND THE DRILLING OF THESE HOLES INTO

THE NEW LONGERONS IS CRITICAL TO THE CORRECT

POSITIONING OF THE LONGERONS IN THE NACELLE.
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(2) Transfer redundant longeron holes onto template as follows:

(a) Position and firmly secure longeron onto its template and scribe reference

outline of longeron.

(b) Use each drain hole as a drill guide and drill thru longeron drain holes into

template.

(c) Separate template from longeron and deburr template.

(d) Secure template and longeron thru newly drilled holes with skin grippers and

drill thru longeron frame retaining holes into template.

(e) Separate template from longeron and deburr template.

(f) Pack and return the removed longeron to Bombardier Aerospace, Customer

Support In-Service Engineering for inspection.

(3) Transfer template holes onto new longeron as follows:

(a) Secure longeron and drilled template thru drain holes with skin grippers and

drill thru template frame retaining holes into longeron.

(b) Separate template from longeron and deburr longeron. Discard template.

(4) Repeat above Step (2) and (3) to each new lower longeron.

(5) Cold work drain holes per SB 8-54-23 (Mod 8/1593).

(6) Install new longerons 85410309 onto both sides of lower structure and secure

into position with skin grippers thru rivet holes in lower frames. Back drill

undersize holes thru structure side skin into longeron. Remove and deburr

longerons. Dimple countersink holes as required.

NOTE: The drilling of full size nacelle skin holes into longerons is completed in

the nacelle. Longerons and packers are installed temporarily in position

onto MLG frames; this will ensure that holes are, and stay, correctly

aligned during drilling.

Part B4: Preparation for Installation of New Lower Longerons and Lower

Structure (Refer to Drawing 8Z9324 sheet 1 and 2 - Observe notes

during installation)

WARNING: LOWER STRUCTURE IS FLEXIBLE AND BULKY. THE ASSISTANCE OF

ADDITIONAL OPERATORS IS REQUIRED TO AVOID POSSIBLE

PERSONAL INJURY DURING INSTALLATION.

NOTE: New longerons and the lower structure are temporarily installed to

determine and ensure their correct positioning within the nacelle structure

prior to final drilling of longerons.
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Revision ‘B’ 13 Mar 2013

(1) Refer to drawing 8Z9324 sheet 1, Detail A, zones 11E thru 19E, install new lower

longerons into nacelle and secure onto upper side frames with skin grippers.

(2) Refer to drawing 8Z9324 sheet 2 arrows C and D, install lower structure into

position in nacelle and secure where possible with skin grippers.

NOTE: Some rivet holes cannot be secured with skin grippers as a result of

pilot-holes in longerons.

(3) Check gap between forward face of longerons and rear face of MLG frames at

inner and outer positions. Peel shims from new packers CSP343-298 and

CSP343-299 as required to fit gaps; install CSP343-298 onto inner position and

install CSP343-299 onto outer position. Do not apply any sealant to packers.

Temporarily secure longerons and packers firmly onto MLG frames with slave

bolts. Lower longerons are in position for final drilling.

NOTE: Each shim is 0.003 inch thickness.

Part B5: Completion to Lower Structure and New Lower Longerons (Refer to

Drawing 8Z9324 Sheets 1 and 2 - Observe notes during installation)

(1) Back drill accessible holes through upper structure side skin into longerons.

Install skin grippers as each hole is drilled.

NOTE: Skin grippers are installed to secure lower structure in position as

remaining holes become accessible for drilling after alignment tubes are

removed.

(2) Back drill remaining holes thru upper structure side skin into longerons.

WARNING: LOWER STRUCTURE IS FLEXIBLE AND BULKY. THE ASSISTANCE OF

ADDITIONAL OPERATORS IS REQUIRED TO AVOID POSSIBLE

PERSONAL INJURY DURING REMOVAL AND INSTALLATION.

(3) Remove skin grippers and carefully lower structure from nacelle.

(4) Remove slave bolts, lower longerons and packers from MLG half-frames. Deburr

longerons. Discard slave bolts.

WARNING: COMPOUNDS AND SOLVENTS ARE HIGHLY FLAMMABLE. KEEP

AWAY FROM FIRE AND OTHER SOURCES OF IGNITION. PROVIDE

SUFFICIENT VENTILATION WHEN WORKING IN CONFINED SPACES.

AVOID CONTACT WITH SKIN. IF SKIN BECOMES IRRITATED, WASH

WITH WATER AND OBTAIN MEDICAL ASSISTANCE.
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(5) Apply anti-corrosive compound F13 grade 2 to shank of new inner bolts.

(6) Fay seal both sides of new packers CSP343-298 and -299 with P/S 870C-80

sealant.

(7) Position packers and new longerons onto rear face of MLG frames.

(8) Refer to drawing 8Z9324 (sheet 2, View on Arrow B) zone 19B thru 21B and

zone 19G thru 21G, install inner bolts, washers and nuts and torque load to 350

inch lbs.

(9) Install lower structure into position in nacelle and secure with skin grippers.

CAUTION: DURING INSTALLATION, REFER TO APPROPRIATE DRAWINGS TO

ENSURE THAT THE CORRECT TYPE, SIZE AND LENGTH OF RIVETS

ARE USED.

(10) Refer to drawing 8Z9324 sheet 2, View on Arrow B, zone 19A thru 21A and zone

19H thru 21H, install new hardware into rear fitting of engine lower support struts

outer hole at lower front of firewall.

(11) Secure with new bolts 81812-8-102 and nuts 81811-820 and new PLI washers

PLI-8-19.6 into longeron, as described in step (12) below.

CAUTION: PRELOAD INDICATING (PLI) WASHERS ARE NOT REUSABLE AND

WHEN BOLT OR NUT ASSEMBLY HAS BEEN LOOSENED A NEW

WASHER ASSEMBLY MUST BE USED.

(12) Install new PLI washer assembly PLI-8-19.6 as follows:

(a) Refer to Figure 1 and install the PLI washer assembly under the head of the

nut.

(b) Tighten the nut until the washers bottom or bind against the inner ring with the

outer ring remaining loose.

(c) Insert an Allen key hex wrench or a twist drill for a close fit into one of the outer

ring test holes. During final torquing, move the ring back and forth slightly until

binding occurs. Stop applying torque; the proper preload has been reached.

If cotter pin hole in bolt and castellation in nut are not aligned sufficiently to

allow pin to be installed, over torque nut to next castellation. Do not over

torque further than one castellation beyond required torque and do not back

off once washer has collapsed.

(d) Install new cotter pins MS24665-306.
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(e) After final torquing, maximum total gaps between the outer concentric ring

and the washers should not exceed 0.010 inches.

(f) All torqued nut and washer assemblies shall be identified with a continuous

thin stripe of suitable paint.

Part B6: Installation of New Angle Brackets and Removed Skin Members to

Nacelle (Refer to Drawing 8Z9324 sheets 1 and 2 - Observe notes

during installation)

(1) Rivet splice strap onto lower center nacelle.

(2) Rivet installed MLG uplock diagonal brace in area of LH and RH lower

longerons.

(3) Rivet retained door actuator stop arm at LH side of nacelle at rear of lower

longeron.

(4) Refer to sheet 2, View on Arrow B, zone 19H and rivet retained angle

85411159-001 onto RH longeron in RH nacelle.

(5) Refer to sheet 2, View on Arrow B, zone 19H and rivet retained angle

8541235-003 onto RH longeron in LH nacelle.

(6) Refer to applicable notes and instructions given in drawing 8Z9324 sheet 1,

install retained drain channels.

(7) Rivet remaining retained angles, brackets, cleats and gussets into position on

longerons, using squeeze gun if required.

Part B7: Installation of Components to Nacelle

(1) Install retained door actuator stop arm 85410512.

CAUTION: USE EXTREME CARE TO AVOID DAMAGING FIRE DETECTION WIRE.

(2) Ensure all bolts are in safety; torque load as required.

(3) Seal firewall gaps with sealant PR1776B2. Refer to applicable instruction in AMM

Chapter 20-21-20.

(4) Apply Alodine, F19 primer and F24 white paint as required. Refer to applicable

instruction in AMM Chapter 20-34-08-00 and Chapter 51-25-01-02.

(5) Apply matching paint to external areas as required.
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CAUTION: REMOVE BLANKS OR CAPS FROM PIPES ONLY WHEN PIPES ARE

READY TO BE CONNECTED.

(6) Refer to AMM Chapter 32-10-11 and install main landing gear.

(7) On LH wall of nacelle install:

(a) All hydraulic tubing along nacelle above longeron, including piping to gear

swivels

(b) Engine drain manifold assembly.

(8) Install engine condition box and associated wiring. Refer to AMM Chapter

71-05-00.

(9) Install main landing gear hydraulic swivels.

(10) Refer to AMM Chapter 32-10-21 and install forward, center and rear main

landing gear doors. Reconnect grounding wires.

(11) Install engine lower cowling.

3. Close Out

(1) Install the fairings to the MLG shock struts (refer to applicable instruction in AMM

Chapter 32-10-31).

(2) Install the main landing gear retraction actuator (refer to applicable instructions

in AMM Chapter 32-30-11).

(3) Service the MLG shock strut (refer to applicable instruction in AMM Chapter

12-10-32).

(4) Do the proximity sensor/target adjustment on the MLG Shock Strut (refer to

applicable instruction in AMM Chapter 32-10-11).

(5) Unlock and close the landing gear doors (refer to applicable instruction in AMM,

Chapter 32-10-21).

(6) Do a functional test of the landing gear extension/retraction system (refer to

applicable instruction in AMM Chapter 32-30-00).

(7) Lower the aircraft off jacks (refer to applicable instruction in AMM Chapter

07-00-00).
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(8) Remove all tools and equipment from the work area.

(9) Do a functional check to all disconnected systems.

(10) On completion of this service bulletin, make the following entry in the

appropriate logbooks: “Service Bulletin 8-54-39 Nacelles - Lower Longeron, Left

and Right Hand Side - Special Inspection and Rectification accomplished.” If

only part of this ModSum / Service Bulletin is completed, use only this service

bulletin number as reference and detail exact limit of work completed. Enter this

ModSum number only after complete and functional incorporation of all work

defined in this service bulletin.
SERVICE BULLETIN 8-54-39

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Installation of PLI Washers

Figure 1

OUTER RING

INNER RING

PLAIN WASHER

TEST HOLE

(3 PLACES)

OUTER CONCENTRIC

RING LOOSE--

INNER RING BOUND

INNER RING COMPRESSED

OUTER RING BOUND

PRE--TORQUED FINAL TORQUE GAP CONDITION

BOLT HEAD

GAP BETWEEN

WASHERS ON

ONE SIDE OF

ASSEMBLY

MAX. TOTAL

GAP 0.010”

PLI--8--19.6 WASHER ASSEMBLY

PLAIN WASHER

STANDARD PLI WASHER ASSEMBLY

PLAIN WASHERS

TORQUE STRIPING--

PLI WASHER / NUT ASSEMBLY

(PRELOAD INDICATING WASHER)
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FRONT

SPAR

REAR

SPAR

LOWER

LONGERON
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4.00in.

(10.2cm)

7.00 in.

(17.8 cm)

THROUGHTHICKNESS

EDM NOTCH INTERFACE-EDGE

EDM NOTCH

ADJUSTABLE TIP

PROBE

COIL

POSITION OF PROBE

DURING BALANCE

TYPICAL
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NOTE

The instrument control set-up with the BXUF-12/16 probe is to be used

as an example only. If you use other instruments or probes, it is possible that a different instrument control set-up will be necessary to

cause the same signal indication.

EDM NOTCH SIGNAL BALANCE POINT

SIGNAL FROM 0.030 in. (0.76 mm)

OUTER EDGE CORNER EDM NOTCH

50%

FSH

ROTARY 33A100

RPM 1500

DISPLAY XY

FREQ. 500 kHz

PHASE 285.0

GAIN 35 dB

X:Y 0.0dB

HI-PASS 150 Hz

LO-PASS 1500 Hz

X-POS 0

Y-POS 0

PERSIST 0.1 sec

INSTRUMENT SETTINGS SCREEN DISPLAY

Eddy Current Signal with Equipment Calibrated

Figure 3
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1

INSTRUMENT SETTINGS SCREEN DISPLAY

ROTARY 33A100

RPM 1500

DISPLAY YT

FREQ. 500 kHz

PHASE 285.0

GAIN 35 dB

X:Y 0.0dB

HI-PASS 150 Hz

LO-PASS 1500 Hz

X-POS 0

Y-POS 0

PERSIST 0.1 sec

EDM NOTCH SIGNAL

50%

FSH

EDM NOTCH

270_ PROBE ROTATION ANGLE

HOLE

SCANNER

MANIPULATION OF SCANNER TO

DETERMINE NOTCH ORIENTATION DIRECTION OF

PROBE ROTATION

90_

180_

MAIN AXIS OF

SCANNER
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2
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