Bombardier415 

MODEL CL-215-6811 (415) 

ALERT 

SERVICE BULLETIN 

NACELLES/PYLONS 

BOMBARDIER 

INSPECTION OF THE BUSHINGS IN THE NACELLE UPPER STRUT ASSEMBLIES 

1. Planning Information 

A. Compliance 

This Service Bulletin is Mandatory. 

The inspection task described in this Service Bulletin must be performed prior to May 30th, 

2013. 

If bushing 8541 0265-1 05 is installed and can only be repaired and not replaced at the time of 

the inspection , then it must be replaced at the next scheduled 5000 hours maintenance check 

or at the next engine removal , which ever comes first. 

NOTE: This Service Bulletin is applicable only to aircraft in the condition as originally 

delivered by Canadair and/or Bombardier Aerospace or as subsequently modified by 

Canadair and/or Bombardier Aerospace Service Bulletin(s) . Prior to incorporation of 

this Service Bulletin, the status of any related systems or structural modification(s) 

introduced by Supplementary Type Approval (STA) or equivalent action must be 

examined for compatibility with the modifications and test procedures (if applicable) 

detailed in this Service Bulletin. 

B. Approval 

The technical content of this Service Bulletin has been approved under the authority of the 

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

C. Effectivity 

CL-215-6B11 (415) turboprop aircraft Serial Nos. 2001 to 2067. 

D. Reason 

Bushings 85410265-105 have been found installed on some in-service aircraft in lieu of 

85410265-103, bushing 85410265-1 05 is shorter than the -1 03 and is not an acceptable 

replacement and is not intended for use on Bombardier 415 nacelles. 

Page 1 of 14 

April 10/12 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
E. Description 

Bombardier 415 

MODEL CL-215-6811 (415) 

ALERT 

SERVICE BULLETIN 

This Service Bulletin gives instructions to do the following: 

- Inspect the bushing 

- Replace the bushing if necessary 

- Repair the bushing if replacement is not possible. 

F. Manpower 

We estimate that it will take one technician approximately 4 hours to complete the inspection 

instructions of this Service Bulletin. 

We estimate that it will take one technician approximately 4 hours to complete the replacement 

instructions of this Service Bulletin. 

We estimate that it will take one technician approximately 4 hours to complete the repair 

instructions of this Service Bulletin. 

G. Material Availability 

Kit No. 215K4453 is necessary to do this Service Bulletin. Information on price and delivery is 

available from your Bombardier Specialized and Amphibious Spares Representative. Bushing 

85410265-103 and repair bushing C415-3902-001 are available through your Bombardier 

Specialized and Amphibious Spares Representative. 

H. Tool Availability 

The following tools (refer to PSP 211) are required to do this inspection: 

- Nacelle mounted engine hoist and sling, 08-0116-5000 (or equivalent) 

OR 

- Engine sling, 08-0112-4000 (or equivalent) 

- Dynamometer or Load cell of a 2500 lbs capacity. 

I. Weight and Balance 

Not affected. 

J. Electrical Load Data 

Not affected. 

K. References 

For Bombardier Aerospace Reference only: 

(Not Supplied with Kit) 

Bombardier Aerospace Restriction and/or Special Instruction (RSI) C-3902, Revision NC. 

Related document: All Operator Message 54-40-00-007, dated Dec 13/11 . 

Page 2 of 14 

April 10/12 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
L. Publications Affected 

None. 

M. Related Service Bulletin 

None. 

2. AccQmQ]ishment_lnstructio[ls 

Bombardier 415 

MODEL CL-215-681 1 (4 15) 

ALERT 

SERVICE BULLETIN 

NOTES: 1. For this modification, it is assumed that standard maintenance and repair practices 

will be applied in accordance with applicable Product Support Publications (PSP). 

2. For parts location, refer to the illustrations in this Service Bulletin. 

3. If any deviation exists, contact your Amphibious Aircraft Technical Representative for 

further instructions. 

4. This inspection is for both the LH and RH nacelle, and there are two bushings in each 

nacelle. 

A. Preparation 

WARNING: ENSURE PERSONNEL AND EQUIPMENT ARE CLEAR OF ALL 

HYDRAULICALLY OPERATED SYSTEMS PRIOR TO REMOVING AIRCRAFT 

ELECTRICAL POWER. 

(1) Isolate electrical power and observe all safety precautions (refer to PSP 492, 

Maintenance Manual, Chapter 24, ELECTRICAL POWER - MAINTENANCE 

PRACTICES). 

B. Access 

(1) Remove lower cowl panel assembly and forward upper cowl panel assembly, as per 

PSP 492, Maintenance Manual, Chapter 71 , POWER PLANT- ENGINE COWLINGMAINTENANCE PRACTICES. 

(2) On LH nacelle, remove access panels 412-1 , 412-2, 412-3, 412-4, 412-5, and 413-3 

as per PSP 492, Maintenance Manual , Chapter 6, ENGINE NACELLES- ACCESS 

PANELS. 

(3) On RH nacelle, remove access panels 422-1 , 422-2, 422-3, 422-4, 422-5, and 423-3 

as per PSP 492, Maintenance Manual, Chapter 6, ENGINE NACELLES- ACCESS 

PANELS. 

Page 3 of 14 

April 10/12 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
C_ Engine Support 

Bombardier 415 

MODEL CL-21 5-6811 (41 5) 

ALERT 

SERVICE BULLETIN 

The nacelle must be in the zero weight condition either by removing the engine from the 

nacelle (option 1) or by supporting the engine in the nacelle (option 2) as described below. 

CAUTION : ENSURE ENGINE SLING LIFT POINT IS POSITIONED TO BALANCE THE 

ENGINE AS CONFIGURED. USE EXTREME CAUTION WHEN SLINGING THE 

ENGINE TO AVOID DAMAGE TO THE HBV ELECTRICAL CONNECTOR AND 

FIRE/OVERHEAT SENSING ELEMENTS LOCATED IN NACELLE. 

OPTION 1 -Engine is removed from Aircraft. Refer to Figure 1.1 

NOTE: Use this option only if the engine is scheduled to be removed from the aircraft, if the 

engine is not scheduled to be removed from the aircraft, then use option 2 for the 

bushing inspection. 

(1) Attach sling to reduction gear box lifting brackets and to engine F flange lifting bracket, 

and remove the engine as shown in PSP 492, Maintenance Manual, Chapter 71 , POWER 

PLANT- TEAR DOWN/BUILD-UP- MAINTENANCE PRACTICES. 

OPTION 2 - Engine is NOT removed from Aircraft. Refer to Figure 1.2 

(2) Calculate total weight to be lifted by adding engine weight (1500 lbs) to weight of lifting 

equipment located under dynamometer or load cell. 

(3) Attach sling to reduction gear box lifting brackets and to engine F flange lifting bracket, as 

shown in PSP 492, Maintenance Manual, Chapter 71, POWER PLANT - TEAR 

DOWN/BUILD-UP - MAINTENANCE PRACTICES. 

(4) Slowly raise hoist until reading on dynamometer or load cell indicates total lifted weight to 

be± 50 lbs of calculated weight to be lifted. 

(5) Make sure the lifting equipment is locked in place and apply appropriate safety tags. 

Page 4 of 14 

April 10/12 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
Bombardier 415 

MODEL CL-215-6811 (4 15) 

ALERT 

SERVICE BULLETIN 

PART A - Inspection of the Bushing 

D. Inspection of the Nacelle Upper Strut Bushing 

Refer to Figure 2 

Do the complete inspection on one strut assembly bushing before starting the other. 

(1) Remove the cotter pin and nut. 

(2) Remove and discard the PLI washer, and retain any washer that is installed between the 

PLI washer and the nut. 

NOTE: PLI (pre-load indicating) washers cannot be re-used and must be discarded 

once removed . 

(3) Remove the bolt 81812-8-30 and the countersunk washer. 

NOTES: 1. Make sure that the strut does not move when the bolt is removed . 

2. If the engine is in the zero weight condition , the bolt should remove with 

minimum resistance. 

(4) Measure the distance "A" as shown in the table on Figure 2 to determine the part number 

of the bushing installed. 

(5) If bushing 85410265-103 is installed, do the section PART A- cont'd, Installation of 

Bolt and PLI Washer, then continue with the inspection of the remaining bushings (both 

upper strut assemblies in both nacelles). 

- or -

(6) If bushing 85410265-105 is installed , do one of the following: 

- PART B - Replacement of the Bushing 

- PART C - Repair of the Bushing 

PART B - Replacement of the Bushing 

E. If bushing 85410265-105 is installed and bushing 85410265-103 is readily available, then 

replace the bushing, as follows: 

(1) Remove the bushing 85410265-105 and discard. 

(2) Check the bushing housing for wear limits, refer to PSP 492, Chapter 54, STRUT 

MOUNTS- INSPECTION/CHECK. 

(3) Install the new bushing 85410265-103, refer to PSP 498, Chapter 20. 

Page 5 of 14 ATA Ref: 54-10 

April 10/12 Service Bulletin 215-A4453 
Bombardier 415 

MODEL CL-215-6811 (415) 

ALERT 

SERVICE BULLETIN 

(4) If necessary, apply a brush nickel plate coating to bare metal of machined area at each 

end of the strut. Refer to PSP 498, Chapter 20. 

(5) Coat the bushing with Mastinox 6856H. 

(6) Continue with PART A- cont'd, Installation of Bolt and PLI Washer 

PART C - Repair of the Bushing 

F. If bushing 85410265-105 is installed and bushing 85410265-103 is not readily available, then 

do the repair, as follows: 

Refer to Figure 4 

(1) Fabricate the bushing C415-3902-001 and rework as per PSP 497, Chapter 51 , REPAIR 

MATERIALS - STANDARD PRACTICES. 

(a) Material is 4130 BAR, AMS-S-6758, heat treat to 125-145 KSI per MIL-H-6875. 

(b) Finish is cadmium plate per 00-P-416 Class 1, Type II. 

(c) Required dimension is .220 ± .01 0. 

(d) The inside diameter is to be parallel and concentric with the outside diameter within 

.0005 total indicator reading . 

(e) Break sharp edges .005" to .015". 

(f) Do a magnetic particle inspection as per ASTM-E 1444, PSP 496 Part 7. 

(g) The surface texture to be 125R HR per ANSI/ASME B46.1. 

(h) Identify (ink stamp) as per PSP 497, Chapter 51 , IDENTIFICATION OF REPAIR 

PARTS AND ASSEMBLIES. 

(2) Install bushing C415-3902-001 wet and transition fit per PSP 498, Chapter 20-53-00, 

PLAIN BUSHING- ASSEMBLY. 

(3) Continue with PART A- cont'd, Installation of Bolt and PLI Washer 

Page 6 of 14 

April 10/12 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
Bombardier 415 

MODEL CL-215-6811 (4 15) 

ALERT 

SERVICE BULLETIN 

PART A - cont'd 

G. Installation of Bolt and PLI Washer 

Refer to Figure 2 and PSP 492, Maintenance Manual, Chapter 54, STRUT MOUNTSREMOVAL/INSTALLATION, Upper Strut- Installation. 

(1) Coat the bolt 81812-8-30 with Mastinox 6856H. 

(2) Install the countersunk washer and the bolt. 

(3) Before fitting the PLI washers, determine the necessary gap for the correct pre-load for 

each PLI washer as follows: 

NOTE: If the bolt and bushing have not been replaced or repaired , then use the retained 

washer, if applicable, that was removed as part of the PLI washer assembly. 

(a) For PLI washer, measure and establish the required gap as follows: 

1 Measure the protrusion of the shank of bolt 81812-8-30. 

2 If protrusion is more than 0.21 inch (5,33 millimetres), add an MS 20002-8 

washer between the PLI washer and the nut. 

(4) Install the PLI washer assembly and nut, then do as follows: 

Page 7 of 14 

April 10/12 

Refer to Figure 3 

(a) Tighten the nut until the outer washer of the PLI washer is against the inner centre 

ring with the outer center ring remaining loose. 

(b) Insert the shank of a drill into one of the test holes in the outer centre ring. 

(c) Rotate the outer center ring back and forth while tightening the nut or the bolt. 

(d) When the outer centre ring binds between the outer washers and can no longer 

rotate, stop tightening. Do not over tighten. The bolt has reached its required 

pre-load. 

(e) Check for gaps between the outer centre ring and both outer washers. A gap of 

0.010 inch (0,25 millimetre) maximum at one of the outer washers or a combined 

total of 0.010 inch (0,25 millimetre) for both sides is acceptable. 

(f) If the slots in the castellated nut do not align sufficiently with either of the holes in the 

bolt to install the cotter pin, tighten the nut to align with the nearest hole. Do not 

tighten more than this. 

(g) Check at nuts that bolt threads are in safety. Refer to PSP 492, Maintenance 

Manual, Chapter 20. 

NOTE: If for any reason, the nut is backed off after the PLI washer assembly has 

been compressed , replace the PLI washer assembly. The PLI washer 

assembly is not re-usable. 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
Bombardier 415 

MODEL CL-215-6611 (41 5) 

ALERT 

SERVICE BULLETIN 

(5) Safety the nut with the cotter pin. 

(6) Torque stripe the heads and tails of bolts, nuts, and washers with a 1/8 inch witness mark 

which extends onto the adjacent structure. Refer to PSP 492, Maintenance Manual, 

Chapter 20. 

(7) Apply a coat of Mastinox 6856H to heads and tails of bolt assemblies. 

H. Completion 

(1) Gently release hoist and remove engine lifting brackets. 

(2) On LH nacelle, install access panels 412-1, 412-2, 412-3, 412-4, 412-5, and 413-3 as 

per PSP 492, Maintenance Manual, Chapter 6, ENGINE NACELLES - ACCESS 

PANELS. 

(3) On RH nacelle, install access panels 422-1, 422-2, 422-3, 422-4, 422-5, and 423-3 as 

per PSP 492, Maintenance Manual, Chapter 6, ENGINE NACELLES- ACCESS 

PANELS. 

(4) Install lower cowl panel assembly and forward upper cowl panel assembly, as per 

PSP 492, Maintenance Manual, Chapter 71 , POWER PLANT- ENGINE COWLING -

MAINTENANCE PRACTICES. 

WARNING: ENSURE PERSONNEL AND EQUIPMENT ARE CLEAR OF ALL 

HYDRAULICALLY OPERATED SYSTEMS PRIOR TO RESTORING AIRCRAFT 

ELECTRICAL POWER. 

(5) Restore electrical power and observe all safety precautions (refer to PSP 492, 

Maintenance Manual, Chapter 24, ELECTRICAL POWER- MAINTENANCE 

PRACTICES). 

I. Recording 

When this Service Bulletin is completed , make the entry in the aircraft log book and send back 

the attached Incorporation Notice to Amphibious Aircraft Technical Publications. 

Page 8 of 14 

April 10/12 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
Bombardier 415 

A. Kit No. 215K4453- Parts List 

PART NO. 

PLI-8-19.6 

MODEL CL-215-6811 (415) 

ALERT 

SERVICE BULLETIN 

QUANTITY 

4 

DESCRIPTION 

PLI washer 

B. The following materials, or equivalent, are necessary to do this Service Bulletin. You can buy 

them locally: 

Page 9 of 14 

April 10/12 

DESCRIPTION 

High Temp. Grease 

White lacquer 

Sealing Compound 

Scotchbrite 

PART NO./NAME 

TI-L-32 

Mastinox 

No. 400 

SPECIFICATION QUANTITY 

MIL-G-25013 A/R 

Fed. Std 595 A/R 

Colour 17875 

6856H A/R 

A/R 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
TRONAIR 

ENGINE HOIST 

AND SLING 

08-0116-5000 

OR EQUIVALENT 

TRONAIR 

ENGINE SLING 

08-0112-4000 

OR EQUIVALENT 

\ 

r·· ------ -' -

Bombardier 415 

MODEL CL-215-6B11 (415) 

ALERT 

SERVICE BULLETIN 

ENGINE HOISTING 

POINTS 

ENGINE REMOVAL 

FIGURE 1.1 

~--------·- OVERHEAD HOIST 

' 'I 

J_~)"" , 

I"~ '\_ a' ----- DYNAMOMETER 

"'-,.._'-'-"-_;} OR LOAD CELL 

.......... I m mmmmmmmmm m I 

NOTE 

Use this method if removing 

the engine is required. 

ENGINE HOISTING -------. I 

POINTS ----.... 

j 

L-------- ~~~~~ HOISTING 

Page 10 of 14 

April 10/12 

ZERO WEIGHT CONDITION IS WHEN 

INDICATED READING (in LBS)=W+X ±50 (in LBS) 

Where. "W" is approximate weight of the engine (in lbs). = 1500 

NOTE 

·x-is weight of the engine sling assembly before setup (in lbs). Use this method if engine 

is not to be removed. ZERO WEIGHT CONDITION OF NACELLE 

FIGURE 1.2 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
Page 11 of 14 

April 10/12 

Bombardier 415 

MODEL CL-215-6811 (415) 

ALERT 

SERVICE BULLETIN 

ACCESS BOLT AND BUSHING 

THROUGH THIS AREA 

OUTBOARD ON LH NACELLE SHOWN 

INBOARD ON LH NACELLE OPPOSITE 

INSPECTION OF THE BUSHINGS IN THE NACELLE STRUT ASSEMBLIES 

FIGURE 2 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
Page 12 of 14 

April 10/12 

Bombardier 415 

MODEL CL-215-6811 (415) 

ALERT 

SERVICE BULLETIN 

0-0 

GAP "A"- PART NUMBER CORRESPONDENCE 

A (in.) PART NUMBER 

Disassembled view of 

Bushing is shown for clarity. 

do not remove from assembly. 

------------.................. - .. --·---·-------

0.040 +/- 0.010 85410265-103 

0.260 +I- 0.010 85410265-105 

INSPECTION OF THE BUSHINGS IN THE NACELLE STRUT ASSEMBLIES 

FIGURE 2 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
Bombardier 415 

OUTER 

WASHERS 

NOTE 

MODEL CL-215-6B11 (415) 

ALERT 

SERVICE BULLETIN 

BEFORE TIGHTENING 

,_ 

INNER CENTRE 

/ RING 

....--""""'+--+'~::---. ______ _ 

"'--OUTER CENTRE 

RING 

Washer assembly comprises two concentric 

steel rings sandwiched between two close 

tolerance plain steel washers. 

2 The PLI-8-19.6 washer has its center ring 

coloured blue (180 KSI), a 1 /2-inch internal 

diameter, and 19,600 LBS nominal preload. 

AFTER TIGHTENING _________ BOLT 

.--'-"4----f-"-"-'-"-,'-..-....____ 

'--.., TEST HOLE 

(3 PLACES) 

PRELOAD INDICATING WASHERS 

AT LOWER LONGERON 

// BUSHING 

STRUT/ / 

/ / //] BOLT/ 

/ [0.25 INCH (6,3 MM) 

/ MAXIMUM 

COUNTERSUNK 

WASHER 

AT HORSE COLLAR AND 

SLOPING LONGERON 

STRUT BUSHING " ~// 

~ 1111111111 

j L0.21 INCH (5,3 MM) 

MAXIMUM 

GAP MEASUREMENT 

Page 13 of 14 

April 10/12 

FIGURE 3 

ATA Ref: 54-1 0 

Service Bulletin 215-A4453 
DIA 0.6875 in. 

DIA 0.6885 in. 

SLNO NUMBER 

1 C415-3902-001 

Page 14 of 14 

April 10/12 

I 

DIA 0.500 in. 

DIA 0.505 in. 

I 

Bombardier 415 

MODEL CL-215-6811 (415) 

ALERT 

SERVICE BULLETIN 

\ 

\ 0 

0.015 in.x45 

CHAMFER 4 PLACES 

BUSHING C415-3902-001 

REPAIR MATERIAL TABLE 

DESCRIPTION I MATERIAL SPECIFICATION 

BUSHING t 4130 BAR. AMS-S-6758, HEAT TREAT TO 125-145 KSI PER MIL-H-6875 

AFTER REPAIR NOTE 

Use bushing C415-3902-001 with 

shear bushing 8541 0265-1 05 

to maintain the gap of 0.040 +/- 0.010 in. 

BUSHING C415-3901-001 DETAILS USED IN REPAIR 

FIGURE 4 

ATA Ref: 54-10 

Service Bulletin 215-A4453 
SERVICE BULLETIN 

INCORPORATION NOTICE 

REPLY FAX 

BOMBARDIER 

Upon completion of Service Bulletin(s), please fill in and return by fax to: 

Service Bulletin Number(s) 

Customer/Operation 

Aircraft Serial No. 

Airframe Hours 

Name 

Technical Publication, 

Dept. 649-DBF-(9) 

Bombardier Aerospace 

Specialized & 

Amphibious Aircraft 

St. Laurent, Quebec 

Fax No.: (514) 855-7602 

Rev. Remarks 

_ Aircraft Reg. No. 

Date of Incorporation 

(Please Print)