MODEL CL-600-2B16

APPENDIX 1 

Basic Issue: Sep 26/2013 A604-57-006 Page 1 of 7 

1 PRIME DESIGN ACTIVITY BOMBARDIER INC. 3AB48 2 REO NUMBER 

BOMBARDIER INC., MONTRÉAL 88308 LEARJET INC. 24210

BOMBARDIER INC., DOWNSVIEW 71867 SHORT BROTHERS PLC K4585

600-57-26-001 

3 TITLE 4 SHEET

GENERAL REPAIR-INBOARD FLAP HINGE BOX- ATTACHMENT FWD 

FITTING FASTENERS

1 OF 7

5 REQUESTED BY 6 ADDITIONAL LIMITATIONS 7 MODEL 8 SERVICE EFFECTIVITY

PCR 1350 NONE CL600/CL601ALL/

CL-604/CL605 

1004-1085, 3001-3066, 5001-5194, 

5301-5665, 5701-6999 

9 DESCRIPTION / DISPOSITION 

DESCRIPTION: 

ON A CHALLENGER CL605 ZONAL INSPECTION, ONE OF THE TWO FORWARD FASTENERS ATTACHING THE INBOARD FWD FLAP HINGE 

FITTINGS AT WS76.50 WAS FOUND WITH ITS HEAD MISSING. 

AN INVESTIGATION DETERMINED THAT WHEN THE FWD FASTENERS WERE ORIENTED WITH THE HEAD OUTSIDE, THOSE FASTENERS 

WILL EXPERIENCE PREMATURE FAILURE. 

ALSO FOUND HI-LITES HOLES NOT PERPENDICULAR TO SURFACE UNDER MANUFACTURED HEAD OF HI-LITES AT FLAP HINGE BOX FWD 

FITTING AT WS76.50 AND WS127.25 (FWD AND AFT FASTENERS LOCATION) 

CORRECTIVE ACTION:

PART A: GIVES INSTRUCTIONS TO INSTALL FWD FASTENERS AT INBOARD FLAP HINGE BOX FWD FITTINGS, WS 76.50 AND 

WS127.25 WITH FASTENER HEAD INSIDE THE WING, WITH NOMINAL, FIRST AND SECOND OVERSIZE HI-LITES(IF NEEDED) 

PART B: GIVES INSTRUCTIONS TO INSTALL AFT FASTENERS AT INBOARD FLAP HINGE BOX FWD FITTINGS, WS 76.50 AND 

WS127.25 WITH FASTENER HEAD OUTSIDE THE WING, WITH NOMINAL, FIRST AND SECOND OVERSIZE HI-LITES(IF NEEDED) 

PERFORM REPAIR ON FWD FITTINGS: 2 FWD FASTENERS FIRST (PART A) AND WHEN FINISHED PROCEED WITH THE 2 AFT 

FASTENERS (PART B). DO NOT REMOVE MORE THAN 2 FASTENERS FROM ONE FITTING AT THE SAME TIME. 

THIS REPAIR IS TO BE CARRIED OUT TO ALL FWD FLAP HINGE FITTINGS AT WS 76.50 AND WS127.25, FWD AND AFT FASTENERS. 

THIS REPAIR IS ONLY APPLICABLE FOR AIRCRAFT WITH TITANIUM FLAP FITTINGS P/N 600-10317-5/-6, 600-10317-951/-952, 600-

10320-7/-8 AND 600-10320-953/-954 

NOTE: THIS REO HAS BEEN RELEASED IN ORDER TO COMPLY WITH THE REQUIREMENTS AS STATED 

IN SB A604-57-006, A605-57-004, A601-0627 AND A600-0763. 

10 REV 

11 DATE 

12 PREPARED BY 

13 STRESS 

14 M&P 

15 

16 DESIGN AUTH 

17 DAO AUTHORITY 

18 RELEASE 

ORIGINAL REO REVISION A, WITH SIGNATURES, KEPT ON FILE.

19 THE TECHNICAL CONTENT OF THIS DOCUMENT IS APPROVED 

UNDER THE AUTHORITY OF TRANSPORT CANADA DESIGN 

APPROVAL ORGANIZATION, DAO NO. 93-Q-02 

BA ENGINEERING DISPOSITION FOR APPROVAL BY 

OPERATOR’S LOCAL AIRWORTHINESS AUTHORITY 

LA PRÉSENTE INSTRUCTION TECHNIQUE DE RÉPARATION A ÉTÉ ÉTABLIE D'APRÈS LES DONNÉES 

FOURNIES À BOMBARDIER INC. PAR L'EXPLOITANT OU PAR SON REPRÉSENTANT. LA RESPONSABILITÉ 

INCOMBE À L'EXPLOITANT OU À SON REPRÉSENTANT DE S'ASSURER QUE TOUTES LES DONNÉES 

FOURNIES SONT COMPLÈTES ET EXACTES. BOMBARDIER INC. DÉCLINE TOUTE RESPONSABILITÉ QUANT 

AUX CONSÉQUENCES RÉSULTANT D'UN RAPPORT DE DOMMAGE OU D'ANOMALIE INCOMPLET OU 

INEXACT.

LES RENSEIGNEMENTS, LES DONNÉES ET DESSINS TECHNIQUES DIVULGUÉS DANS LES PRÉSENTES 

SONT LA PROPRIÉTÉ EXCLUSIVE DE BOMBARDIER INC. OU COMPORTENT DES DROITS DE PROPRIÉTÉ 

APPARTENANT À AUTRUI ET NE PEUVENT ÊTRE DIVULGUÉS À QUICONQUE NI UTILISÉS PAR QUI QUE CE 

SOIT SANS LE CONSENTEMENT ÉCRIT DE BOMBARDIER INC. LE DÉTENTEUR DES PRÉSENTES S'ENGAGE, 

DANS TOUTES CIRCONSTANCES, À GARDER CONFIDENTIELS LES DONNÉES ET DESSINS TECHNIQUES 

QU'ELLES CONTIENNENT. CE QUI PRÉCÈDE NE S'APPLIQUE PAS AUX PERSONNES QUI ONT DES DROITS 

DE PROPRIÉTÉ SUR CES RENSEIGNEMENTS, DONNÉES TECHNIQUES ET DESSINS DANS LA MESURE OÙ 

CES DROITS EXISTENT.

THIS REPAIR ENGINEERING ORDER HAS BEEN PREPARED ON THE BASIS OF INFORMATION SUPPLIED TO 

BOMBARDIER INC. BY THE OPERATOR OR HIS AGENT. IT IS THE RESPONSIBILITY OF THE OPERATOR OR 

HIS AGENT TO VERIFY THAT THE INFORMATION SUPPLIED IS COMPLETE AND ACCURATE. BOMBARDIER 

INC. DOES NOT ACCEPT RESPONSIBILITY FOR ANY CONSEQUENCE RESULTING FROM INCOMPLETE OR 

INACCURATE REPORTING OF THE DAMAGE / DISCREPANCY.

THE INFORMATION, TECHNICAL DATA AND DESIGNS DISCLOSED HEREIN ARE THE EXCLUSIVE PROPERTY 

OF BOMBARDIER INC. OR CONTAIN PROPRIETARY RIGHTS OF OTHERS AND ARE NOT TO BE USED OR 

DISCLOSED TO OTHERS WITHOUT THE WRITTEN CONSENT OF BOMBARDIER INC. THE RECIPIENT OF THIS 

DOCUMENT, BY ITS RETENTION AND USE AGREES TO HOLD IN CONFIDENCE THE TECHNICAL DATA AND 

DESIGNS CONTAINED HEREIN. THE FOREGOING SHALL NOT APPLY TO PERSONS HAVING PROPRIETARY 

RIGHTS TO SUCH INFORMATION, TECHNICAL DATA OR SUCH DESIGNS TO THE EXTENT THAT SUCH 

RIGHTS EXIST. D.3363-27 REV 1999-07

X
MODEL CL-600-2B16

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Basic Issue: Sep 26/2013 A604-57-006 Page 2 of 7 

GENERAL NOTES: 

1. FINISH CODES PER SRM PSP607 CH.51-58-138/42 (CL600/CL601) OR SRM CL604/CL605 CH.51-01-04 OR BAERD GEN004 

2. INSTALL HI-LITES INTERFERENCE FIT, (EXCEPT HOLES IN TITANIUM FITTINGS) AS PER SRM PSP607 CH.51-43-01 / SRM CL604-

CL605 CH.51-42-36 OR BAPS151-029. 

WARNING 

WHEN INSTALLING HI-LITES ENSURE A FULL CONTACT BETWEEN HEAD AND 

ADJACENT UNDER SURFACE. DO NOT FORCE CONTACT BY HITTING THE HEAD OF HILITE WITH A HAMMER OR OTHER TOOL. THIS REO PROVIDE INSTRUCTIONS TO 

REPAIR INSTALLATION IN ORDER TO HAVE A FULL CONTACT. 

CAUTION 

DO NOT DRILL OFF HEADS OF HI-LOKS / HI-LITES AND DRIVE SHANK INTO WING BOX 

AS THIS COULD CAUSE SEVERE SCORING OF THE HOLES. REMOVE COLLAR AND 

DRIVE HI-LOK / HI-LITES FROM THREADED END. 

3. WET INSTALL HI-LITES PER SRM PSP607 CH.51-57-00 / SRM CL604-CL605 CH.51-23-04 / SPM 51-23-00 

4. IT IS PERMISSIBLE TO INSTALL FIRST OVERSIZE HI-LITE HST154AG8-( ) IN LIEU OF NOMINAL HI-LITE HST54AG8-( ) 

5. IT IS PERMISSIBLE TO INSTALL SECOND OVERSIZE HI-LITE HST254AG8-( ) IN LIEU OF FIRST OVERSIZE HI-LITE HST154AG8-( ) 

6. INTERMIXING NOMINAL, FIRST AND SECOND OVERSIZE HI-LITES IS ACCEPTABLE. 

7. IT IS PERMISSIBLE TO USE HI-LITE HST54AC8-( ) OR HST54AP8-( ) OR HST54AZ8-( ) IN LIEU OF HST54AG8-( ) 

8. IT IS PERMISSIBLE TO USE HI-LITE HST154AC8-( ) OR HST154AP8-( ) OR HST154AZ8-( ) IN LIEU OF HST154AG8-( ). 

9. IT IS PERMISSIBLE TO USE HI-LITE HST254AC8-( ) OR HST254AP8-( ) OR HST254AZ8-( ) IN LIEU OF HST254AG8-( ). 

10. BRUSH COAT FASTENERS HEADS INSIDE FUEL TANK (WS127.25) AND FILL ALL THE GAPS AS PER SRM PSP607 CH.51-57-00 / 

SRM CL604-CL605 CH.51-23-04 / SPM 51-23-00 

Changes from Rev NC: 

Sh.1: 

-Text in “Corrective Action” different to be clearer. Allow to perform repair 2 fasteners same time per fitting in lieu of 1 per fitting 

Sh.2: 

-Added note 3, 7 and 10. Note 6 Changed. Note numbering changed to accommodate new notes. 

Sh.3 

-In Fig.1 length of Hi-Lites indicated to avoid confusion. Added note that Hi-Lite length should be adjusted on instl. 

Sh.4-5-6: (previous 4-5) 

-Added Note: For FWD fasteners rework it is not necessary to disconnect flap hinge box. 

-Text was reorder to be clearer 

-Shim PN changed, added shims dimensions in sh.5 

-Spotfacing dia allow being smaller to avoid interference 

-Removed option for tapered shim 

-Added NOTE: Length of Hi-Lites is suggested. User proper length to suit instl. 

Sh.7 (previous Sh.6) 

-Reorder to be clearer 

-Added note for Hi-Lite removal 
MODEL CL-600-2B16

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FIGURE 1 

FWD 

LENGHT OF HI-LITES SHOULD BE ADJUSTED ON INSTALLATION 
MODEL CL-600-2B16

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PART A: THIS REPAIR IS APPLICABLE ONLY TO FWD FASTENERS AT WS76.50 AND WS127.25 (SEE FIGURE 1) 

NOTE: FOR FWD FASTENER REWORK IT IS NOT NECESSARY TO DICONNECT FLAP HINGE BOX. 

1. REMOVE EXISTING FASTENER. 

CAUTION 

DO NOT DRILL OFF HEADS OF HI-LOKS/HI-LITES AND DRIVE SHANK INTO 

WING-BOX AS THIS COULD CAUSE SEVERE SCORING OF THE HOLES. 

REMOVE COLLAR AND DRIVE HI-LOK/HI-LITE FROM THREADED END. 

2. INSPECT AROUND THE HOLE FOR MARKS, GOUGES ETC. OVER FITTING P/N 600-10317-5/-6 (WS76.50) / 600-10320-7/-8 (WS127.25). 

3. IF DAMAGE IS FOUND PERFORM SPOT FACING 0.625 DIA X 0.062R IN LINE WITH EXISTING HOLE OVER FITTING 600-10317 / 600-

10320. SPOT FACING DEPTH SHOULD BE THE MINIMUM TO REMOVE DAMAGE AND ENSURE A FULL CONTACT SURFACE FOR NUT 

KFN674-4. MAX DEPTH 0.007” AND MIN. REMAINING FITTING THICKNESS SHOULD BE 0.243”. FLUORESCENT PENETRANT 

INSPECTION PER SRM PSP607 CH.51-18-00 / NDTM, PART 8, SECTION 1 TO ENSURE REWORKED AREA IS CRACK FREE. RESTORE 

FINISH T022, COLOR GREY #16473 PER FED.STD.595 

WARNING 

IF PREVIOUS SPOT FACING EXIST, THE MAX TOTAL DEPTH IS 0.007” 

(PREVIOUS SPOT FACING + NEW SPOT FACING) AND MIN. REMAINING 

FITTING THICKNESS SHOULD BE 0.243” 

4. TO ENSURE NO GAP UNDER THE HEAD AND A PERPENDICULAR SURFACE PROCEED AS FOLLOWS (SEE FIGURE 2 AND 3) 

A. MANUFACTURE SHIM P/N 600-57-26-001-001/-002/-003/-004/-005/-006/-007/-008 AS PER FIGURE 3: MATERIAL AL.AL.7075-T6, PER 

SAE AMS-QQ-A-250/12 OR AL.AL 2024-T3 OR T4 PER SAE AMS-QQ-A-250/4, THICKNESS: 0.063”. IT IS PERMISSIBLE TO TRIM TO 

SUIT RADIUS AND SHAPE OF MACHINED PARTS AROUND. FINISH A022. 

B. BOND SHIMS TO STRUCTURE OVER THE HOLE (SEE FIGURE 3) AS PER SRM PSP607 CH.51-55-11 (CL600-CL601) OR SPM 

CH.51-24-05 (CL604-CL605) OR BAPS155-079. ENSURE ADHESIVE IS COMPLETELY CURED BEFORE CONTINUING. IT IS 

PERMISSIBLE TO OPEN A SMALL HOLE IN SHIMS TO CLAMP SHIM USING A TEMPORARY FASTENER OR BOLT-WASHER-NUT 

WHILE ADHESIVE IS CURING. 

C. OPEN HOLE IN SHIM CONCENTRIC FROM EXISTING HOLE IN STRUCTURE (SAME DIA AS EXISTING HOLE IN STRUCTURE) 

D. BACK SPOT FACING 0.625 DIA SHIM P/N 600-57-26-001-00X IN ORDER TO GET A FULL CONTACT SURFACE FOR HI-LITE HEAD. 

PERFORM THE SPOT-FACING CAREFULLY, IN SEVERAL STEPS, IN ORDER TO AVOID MACHINE THRU SHIM AND DAMAGE 

EXISTING INNER FITTING. RESTORE FINISH A022. 

NOTE 

IF CUTTER INTERFERES WITH ADJACENT STRUCTURE, IT IS PERMISSIBLE TO 

USE SMALLER SPOTFACING DIA ENSURING THAT FLAT SURFACE IS BIGGER 

THAN HI-LITE HEAD DIA. 
MODEL CL-600-2B16

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FIGURE 3: SHIMMING 
MODEL CL-600-2B16

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5. INSPECT INSIDE FASTENER HOLES FOR DAMAGE, GAUGES, MARKS, CORROSION, ETC. VERIFY DIAMETER. 

6. IF HOLE IS DAMAGED OR ENLARGED PROCEED AS FOLLOWS: 

A. OPEN HOLE TO DIA .2606-.2636 FOR FIRST OVERSIZE (DIA .2762-.2792 FOR SECOND OVERSIZE) (SEE FIGURE 4) 

B. OPEN HOLE IN FITTING P/N 600-10317/600-10320 TO DIA .2766-.2792 FOR FIRST OVERSIZE (DIA .2918-.2948 FOR SECOND 

OVERSIZE). USE A CONTROLLED COUNTERBORE TO ENSURE PASS THRU THE FITTING 600-10317/600-10320 BUT DO NOT 

TOUCH THE WINGPLANK. IT IS ACCEPTABLE TO TOUCH THE SHIM S-5178. (SEE FIGURE 4) 

7. MAKE A CHAMFER RELIEF ON REO SHIM 600-57-26-001-00X AS PER SRM PSP607 CH.51-40-21 (CL600-CL601), SRM CL604/CL605 

CH.51-40-08 OR BAPS151-029 

8. FINISH ALL BARE METAL SURFACES CODE A022 (DO NOT PAINT INSIDE HOLE AND CHAMFER RELIEF) 

9. INSTALL HI-LITE HST54AG8-12 (OR HST154AG8-12 FOR FIRST OVS OR HST254AG8-12 FOR SECOND OVERSIZE) PIN AND KFN674-4 

NUT FOR THE FITTING 600-10317 (WS 76.50) AND HI-LITE HST54AG8-11 PIN (OR HST154AG8-11 FOR FIRST OVS OR HST254AG8-11 

FOR SECOND OVERSIZE) AND KFN674-4 NUT FOR THE FITTING 600-10320 (WS127.25) WITH THE HEAD INSIDE OF WING BOX AS 

SHOWN IN FIGURE 1. 

WARNING 

WHEN INSTALLING HI-LITES ENSURE A FULL CONTACT BETWEEN HEAD AND 

ADJACENT UNDER SURFACE. DO NOT FORCE CONTACT BY HITTING THE HEAD OF HILITE WITH A HAMMER OR OTHER TOOL. 

NOTE 

LENGHT OF HI-LITES IS SUGGESTED. USE PROPER LENGHT TO SUIT INSTALLATION. 
MODEL CL-600-2B16

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Basic Issue: Sep 26/2013 A604-57-006 Page 7 of 7 

PART B: THIS REPAIR IS APPLICABLE ONLY TO AFT FASTENERS (SEE FIGURE 1) 

NOTE: FOR AFT FASTENER REWORK IT IS NECESSARY TO DICONNECT FLAP HINGE BOX. 

1. REMOVE EXISTING FASTENER. 

CAUTION 

DO NOT DRILL OFF HEADS OF HI-LOKS/HI-LITES AND DRIVE SHANK INTO 

WING-BOX AS THIS COULD CAUSE SEVERE SCORING OF THE HOLES. 

REMOVE COLLAR AND DRIVE HI-LOK/HI-LITE FROM THREADED END. 

2. INSPECT AROUND THE HOLE FOR MARKS, GOUGES ETC. OVER FITTING P/N 600-10317-5/-6 (WS76.50) / 600-10320-7/-8 (WS127.25). 

INSPECT ALSO FOR GAPS UNDER HEAD AND PERPENDICULARITY BETWEEN SURFACE AND FASTENER HOLE TO ENSURE A FULL 

CONTACT BETWEEN HI-LITE HEAD AND SURFACE. 

3. IF DAMAGE IS FOUND AND/OR A GAP OR NOT PERPENDICULARITY IS FOUND PERFORM SPOT FACING 0.625 DIA X 0.062R IN LINE 

WITH EXISTING HOLE (SEE FIGURE 5). SPOT FACING DEPTH SHOULD BE THE MINIMUM TO REMOVE DAMAGE AND ENSURE A 

FULL CONTACT SURFACE FOR HI-LITE HEAD. MAX DEPTH 0.010” AND MIN. REMAINING FITTING THICKNESS SHOULD BE 0.240”.

FLUORESCENT PENETRANT INSPECTION PER SRM PSP607 CH.51-18-00 / NDTM, PART 8, SECTION 1 TO ENSURE REWORKED 

AREA IS CRACK FREE. 

WARNING 

IF PREVIOUS SPOT FACING EXIST, THE MAX TOTAL DEPTH IS 0.010” 

(PREVIOUS SPOT FACING + NEW SPOT FACING) AND MIN. REMAINING 

FITTING THICKNESS SHOULD BE 0.240” 

4. INSPECT INSIDE FASTENER HOLES FOR DAMAGE, GAUGES, MARKS, CORROSION, ETC. VERIFY DIAMETER IF HOLE IS DAMAGED 

OR ENLARGED PROCEED AS FOLLOWS: 

A. OPEN HOLE TO DIA .2606-.2636 FOR FIRST OVERSIZE (DIA .2762-.2792 FOR SECOND OVERSIZE) (SEE FIGURE 4) 

B. OPEN HOLE IN FITTING P/N 600-10317/600-10320 TO DIA .2766-.2792 FOR FIRST OVERSIZE (DIA .2918-.2948 FOR SECOND 

OVERSIZE). USE A CONTROLLED COUNTERBORE TO ENSURE PASS THRU THE FITTING 600-10317/600-10320 BUT DO NOT 

TOUCH THE WINGPLANK. IT IS ACCEPTABLE TO TOUCH THE SHIM S-5178. (SEE FIGURE 4) 

5. MAKE A CHAMFER RELIEF AS PER SRM PSP607 CH.51-40-21 (CL600-CL601), SRM CL604/CL605 CH.51-40-08 OR BAPS151-029. 

6. RESTORE FINISH T022, COLOR GREY #16473 PER FED.STD.595 (DO NOT PAINT INSIDE HOLE AND CHAMFER RELIEF) 

7. INSTALL HI-LITE HST54AG8-12 PIN (OR HST154AG8-12 FOR FIRST OVS OR HST254AG8-12 FOR SECOND OVS) AND KFN674-4 NUT 

WITH THE HEAD OF HI-LITE OVER FITTING 600-10317 (WS 76.50) / 600-10320 (WS127.25) AS SHOWN IN FIGURE 1. 

WARNING 

WHEN INSTALLING HI-LITES ENSURE A FULL CONTACT BETWEEN HEAD AND 

ADJACENT UNDER SURFACE. DO NOT FORCE CONTACT BY HITTING THE HEAD OF HILITE WITH A HAMMER OR OTHER TOOL.