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 Effectivitysection is added

- the Problem part of theReasonsection 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 Referencessection is revised to convey the latest revision of the service bulletin and engineering documentation

- the Detailed Kit Content of theParts Required Per Aircraftsection 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 14 Mar 2012 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

S.B. 8-54-39 Page 2 of 32 14 Mar 2012 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 toeach 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 Page 3 of 32 14 Mar 2012 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 EddyCurrent (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

S.B. 8-54-39 Page 4 of 32 14 Mar 2012 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

S.B. 8-54-39 Page 5 of 32 14 Mar 2012 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. MATERIALINFORMATION
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 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 Quantity Per Kit -001 Remarks Description Part Number

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

S.B. 8-54-39 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

S.B. 8-54-39 Page 10 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 Part Number Remarks Description Qty. Per Aircraft 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

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 11 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 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).

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 12 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 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 lessthan 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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 13 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 (2) If no cracks are found and aircraft has morethan 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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 14 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 (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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 15 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 (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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 16 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 (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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 17 of 32 14 Mar 2012 NB 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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 18 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 (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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 19 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 (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.

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 20 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 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).

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 21 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 (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

S.B. 8-54-39 Page 22 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 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)

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 23 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 24 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 25 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 26 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 27 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 FRONT SPAR REAR SPAR

LOWER LONGERON

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 28 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 29 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 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

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 30 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 NOTE The instrument control set-up with the BXUF-12/16 probe is to be usedas 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

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 31 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 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 TODETERMINE NOTCH ORIENTATION DIRECTION OF PROBE ROTATION 90_ 180_ MAIN AXIS OF SCANNER

### SERVICE BULLETIN 8-54-39

S.B. 8-54-39 Page 32 of 32 14 Mar 2012 NB Revision ‘B’ 13 Mar 2013 

### This Page Intentionally Blank 2Jan 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 V Compliance VApproval V Manpower V Material VWeight and Balance V Electrical Load VTooling 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 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